Modularization And Structural Lowcarbon Optimization Design Of Composite Mold For Patternless Sand Casting

The sand casting process has the problems of high resource consumption,high carbon emissions and environmental pollution.The traditional sand casting method cannot meet the requirements of forming castings with complex structures,and when the patternless sand casting method is used,it can effectively meet the requirements of forming complex types of castings.At present,in the patternless sand casting typical use of 3D printing,milling processing and other casting forming methods,compared with traditional casting forming methods,three types of forming methods in forming efficiency,cost,accuracy,resource consumption,carbon emissions and application occasions have their own characteristics and advantages,how to give full play to the advantages of the above three forming methods,effectively reduce the carbon emissions of the moldless sand casting process is a worthwhile research.This paper focuses on the characteristics of the patternless sand casting process,combining 3D printing,milling forming and traditional molding methods with mold modularization to form a composite mold method using different mold forming methods,on the basis of which a low carbon optimization method for the mold structure is proposed according to the characteristics of the mold module,and ultimately,through the above research,the carbon emissions and resource consumption of the patternless sand casting process are reduced.The main research contents include:1)According to the characteristics of 3D printing,milling forming and traditional mold forming methods,the principle of modularization of composite molds using different mold forming methods is proposed,and a certain type of cylinder block mold example is used for mold division.2)The patternless sand casting process is divided into two stages:mold forming and post-pouring processing.The mold forming stage mainly uses traditional molding,3D printing and sand milling.Based on the materials,energy,and undesired carbon sources of these two stages,a carbon emission model of patternless casting is established.And on this basis,taking a certain type of cylinder block as an example,three modularization division schemes are drawn up,and the degree of impact of different division methods on carbon emissions is analyzed.3)According to the characteristics of different mold modules,the wall thickness of the mold modules and the assembly of the mold modules were optimized for low carbon structure.By adopting this structural optimization method,modeling materials and energy consumption can be effectively reduced,and the goal of energy saving and emission reduction in the sand casting process can be achieved.4)This paper takes a certain type of cylinder block casting as an example,respectively adopts the casting process plan based on a single mold and three casting process plans based on the modularization division of the composite mold to shape the cylinder block,and on this basis,the mold structure is optimized for low carbon.The comparative analysis of casting carbon emissions verifies the effectiveness of composite mold with different forming methods in terms of energy saving and emission reduction compared with single mold.Secondly,when the composite mold module is divided,the sand mold milling module uses a concave mold and the 3D printing module has a small volume,which has more low-carbon benefits.At the same time,the use of composite mold with optimized lowcarbon structure further reduces carbon emissions during the sand casting process and verifies the feasibility of the method.Through the research results of this paper,the modularization method of composite mold and the low-carbon optimization method of mold structure have been adopted to reduce the resource consumption and carbon emissions of the patternless sand casting process,so as to provide technical support for the sustainable development of the traditional foundry industry.