Burner Metal Casting Production System Improvements

Casting technology is a fundamental technology in mechanical manufacturing industry and one of the principal techniques for national economy sustainable development at the mean time. With the accelerated process of global economic integration and environmental protection, it is inevitable to promote the technology transformation of traditional foundry production system.Burner casting was taken as the research object of this paper. Based on system analysis of burner production system at present, the existing main problems were identified and a general improvement scheme was proposed. Then the research was conducted according to two key issues, one is that the current heating equipment's problems as its old style, high energy consumption, low thermal efficiency, severe environment pollution and uncontrolled combustion temperature. And the other issue includes its thermal fatigue crack failure and short service life for the permanent mold of casting burner. Based on the two issues, the following works were carried out.Firstly, after analysis of the characteristics of various heating methods and comparing their advantages and disadvantages, the heating program was presented and the furnace type was selected. According to the actual production needs, the furnace was overall designed considering transportation structure, the design of furnace chamber's structure, the heating power and so on.Secondly, model of the burner casting and casting molds were built by Pro/E. The teeming and solidification process was simulated with ProCAST. Then the temperature and stress field of the mould were analyzed. The results showed that the largest thermal stress area is basically consistent with the area where thermal fatigue failure often occurred so that the accuracy of the numerical simulation was verified.Finally, the reasons for metal mould's low life based on the simulation results were listed. The mould temperature and stress field were simulated at different pouring temperature, mould preheat temperature, pouring velocity and mould material. Then the influence law of factors mentioned above was accordingly obtained. At last, an improvement scheme was introduced, with which the stress of casting mold obviously reduced and the service life significantly increased.