CN219881304U - Intelligent molding production line of dragon rib plate - Google Patents

Intelligent molding production line of dragon rib plate Download PDF

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Publication number
CN219881304U
CN219881304U CN202320990840.1U CN202320990840U CN219881304U CN 219881304 U CN219881304 U CN 219881304U CN 202320990840 U CN202320990840 U CN 202320990840U CN 219881304 U CN219881304 U CN 219881304U
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machine
molding
track
pouring
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夏小江
疏达
盛云庆
汪东红
周昊奕
洪华泽
朱国
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Shanghai Jiaotong University
Zhejiang Institute of Mechanical and Electrical Engineering Co Ltd
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Shanghai Jiaotong University
Zhejiang Institute of Mechanical and Electrical Engineering Co Ltd
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Abstract

The utility model discloses an intelligent molding production line of a keel plate, which comprises a molding section, a pouring section, a box opening cleaning section, a control system and an iron mold; the rear section of the modeling section is provided with a pouring section, and the rear section of the pouring section is provided with a box opening cleaning section; the modeling section, the pouring section and the unpacking cleaning section are respectively connected with the control system; the iron mold sequentially runs through a molding section, a pouring section and a unpacking cleaning section; the iron mold is used for casting molding of the keel plate. The utility model can realize intelligent molding of the keel plate and has the advantages of high production efficiency and good production quality.

Description

Intelligent molding production line of dragon rib plate
Technical Field
The utility model relates to the technical field of metal part forming, in particular to an intelligent forming production line of a keel plate.
Background
The cross beam casting is taken as a typical metal piece, is long and narrow, has uneven thickness, aims at the problem that the cross beam casting is deformed after being subjected to the effects of temperature, external force and internal stress in the processes of solidification, cooling, shakeout and the like, and generally counteracts the deformation degree of a final product by modifying a mould and designing an inverse deformation amount on the mould according to the condition of repeated trial production, but is influenced by the comprehensive influence of various factors, and the deformation amount is difficult to ensure.
The digital infrastructure of the metal part forming production line is weak, data acquisition is lacking, or the data acquisition is not infiltrated into the process parameter adjustment. The flow and solidification of high-temperature metal liquid in the forming process make the material and energy transfer very complex, the process parameters are many and the process parameters are interrelated, so that the function model has the characteristics of high nonlinearity, strong coupling and time variability, and therefore, the optimal process parameters are difficult to find.
In actual production, the control of process parameters is often unsatisfactory due to the interference of the field environment, and when the control of the process parameters of the executed process deviates, the unexecuted process can only be executed according to the original plan, so that the molding effect is poor in the case.
Disclosure of Invention
The utility model aims to provide an intelligent molding production line for a keel plate. The utility model can realize intelligent molding of the keel plate and has the advantages of high production efficiency and good production quality.
The technical scheme of the utility model is as follows: the intelligent molding production line of the keel plate comprises a molding section, a pouring section, a unpacking cleaning section, a control system and an iron mold; the rear section of the modeling section is provided with a pouring section, and the rear section of the pouring section is provided with a box opening cleaning section; the modeling section, the pouring section and the unpacking cleaning section are respectively connected with the control system; the iron mold sequentially runs through a molding section, a pouring section and a unpacking cleaning section; the iron mold is used for casting molding of the keel plate.
The intelligent molding production line of the keel plate comprises a molding section, wherein the molding section comprises a first rail, a molding machine is arranged on the first rail, a first box turning machine is arranged at the rear section of the molding machine, and a box closing machine is arranged at the rear end of the first box turning machine.
According to the intelligent molding production line for the keel plates, the casting section comprises the second rail, and one side of the second rail is provided with the casting machine and the casting trolley arranged on the second rail; the pouring trolley is used for bearing and transporting iron forms; the casting machine is used for casting molten iron into the iron mold after the mold closing.
The intelligent molding production line of the dragon rib plate, the unpacking cleaning section comprises a third rail, the unpacking machine is arranged on the third rail, the rear section of the unpacking machine is provided with the casting machine, the rear section of the casting machine is provided with the second box turning machine, the rear section of the second box turning machine is provided with the vibration shakeout machine, and the rear section of the vibration shakeout machine is provided with the third box turning machine.
In the intelligent molding production line for the keel plates, the first track is parallel to the third track; the second track is provided with two parallel sections, the first section is connected to the rear end of the first track, the second section is connected to the front end of the third track, and the rear end of the first section is connected with the front end of the second section through a track transfer system; and the junction of the second track and the first track and the junction of the second track and the third track are both provided with a suitcase machine.
In the intelligent molding production line of the keel plate, a detection system is arranged in the control system and comprises a first temperature sensor, a second temperature sensor, a third temperature sensor, a fourth temperature sensor, a first timer, a second timer and a displacement deformation measuring instrument; the first temperature sensor is arranged on a roller way in front of the molding machine; the second temperature sensor is arranged in the molding machine; the third temperature sensor is positioned in front of the pouring trolley; the fourth temperature sensor is positioned above the pouring trolley; the first timer is arranged in the molding machine; the second timer is positioned on the pouring trolley and the box opening machine; the displacement deformation measuring instrument is positioned on the casting machine.
The intelligent molding production line of the keel plate comprises an upper iron mold and a lower iron mold; the surfaces of the upper iron mold cavity and the lower iron mold cavity are covered with sand layers, and the surfaces of the sand layers are consistent with the shape of a metal model of a keel plate in the molding machine in shape and are provided with reverse deformation.
Compared with the prior art, the intelligent molding production line of the keel plates can realize the intelligent molding of the keel plates, and the intelligent molding production line of the keel plates is produced through three-section work of a molding section, a pouring section and an unpacking cleaning section, so that the effects of high production efficiency and good production quality are realized. Aiming at the problem of low digitization level of a metal part forming production line, the utility model adopts a temperature sensor, a timer and a displacement deformation measuring instrument, thereby realizing the acquisition of production line data. The utility model can optimize the technological parameters of the non-executed process in real time according to the condition of the executed process, and effectively control the quality of the product.
Drawings
FIG. 1 is a schematic diagram of a production line setup of the present utility model;
FIG. 2 is a schematic diagram of a production line inspection apparatus of the present utility model;
FIG. 3 is a schematic view of the structure of the cast iron-containing mold of the present utility model;
FIG. 4 is a flow chart of the process parameter real-time optimization of the present utility model;
FIG. 5 is a flow chart of the utility model for calculating the reverse deformation of the metal model of the keel plate;
FIG. 6 is a schematic diagram of a neural network functional model architecture of the present utility model;
FIG. 7 is a flowchart of the genetic algorithm optimization process of the present utility model.
Reference numerals
1-molding section, 11-molding machine, 12-first box turner, 13-box closing machine, 2-pouring section, 21-first rail, 22-second rail, 23-pouring trolley, 24-pouring machine, 25-rail transfer system, 26-box lifting machine, 27-third rail, 3-box opening cleaning section, 31-box opening machine, 32-casting machine, 33-second box turner, 34-vibration shakeout machine, 35-third box turner, 4-control system, 41-first temperature sensor, 42-second temperature sensor, 43-first timer, 44-third temperature sensor, 45-fourth temperature sensor, 46-second timer, 47-displacement deformation measuring instrument, 5-iron type, 51-upper iron type, 52-lower iron type, 53-cover sand layer, 54-keel plate.
Detailed Description
The utility model is further illustrated by the following figures and examples, which are not intended to be limiting.
Example 1: an intelligent molding production line of a keel plate is shown in fig. 1, and comprises a rail system, a control system 4 and an iron mold 5; the rail system is provided with a modeling section 1, a casting section 2 is arranged at the rear section of the modeling section 1, and a box opening cleaning section 3 is arranged at the rear section of the casting section 2; the modeling section 1, the pouring section 2 and the unpacking cleaning section 3 are respectively connected with the control system 4; the iron mold 5 sequentially runs through a modeling section 1, a pouring section 2 and an unpacking cleaning section 3 of the track system and circulates in a anticlockwise sequence; the iron mold 5 is used for Long Jinban casting molding. As shown in fig. 2, the iron mold 5 includes an upper iron mold 51 and a lower iron mold 52; the sand coating 53 is attached to the surfaces of the cavities of the upper iron mold 51 and the lower iron mold 52, and the surface of the sand coating 53 is provided with reverse deformation in accordance with the shape of the metal model of the keel plate in the molding machine 11. The iron mold 5 is provided with a keel plate 54 after casting, and the shape of the keel plate 54 is consistent with the shape of the cavity after sand coating, and the keel plate has reverse deformation. After the upper iron mold 51 and the lower iron mold 52 are closed, pouring molten iron into a cavity of the upper iron mold 51 and the lower iron mold 52 to obtain a keel plate 54; the sand coating 53 has an inverse deformation amount for counteracting the deformation amount generated in the molding process of the gusset 54.
As shown in fig. 1, the track system includes a first track 21, a second track 22, a third track 27, a track change system 25, and a tote machine 26; the first track 21 is parallel to the third track 27; the second track 22 has two parallel sections, the first section is connected to the rear end of the first track 21, the second section is connected to the front end of the third track 27, and the rear end of the first section is connected to the front end of the second section through a track transfer system 25; the suitcase machine 26 is arranged at the junction of the second rail with the first rail 21 and the third rail 27.
As shown in fig. 1, the molding section 1 comprises a molding machine 11 arranged on a first track 21, a first box turnover machine 12 is arranged at the rear section of the molding machine 11, and a box closing machine 13 is arranged at the rear end of the first box turnover machine 12. Designing an inverse deformation amount of a metal model in the molding machine 11, wherein the inverse deformation amount in the model is determined according to an optimization result of a control system; the reverse deformation of the metal mold is used to counteract the deformation of the gusset 54 during the molding process. The molding machine 11 is coated with a sand coating 53 on the metal mold inner cavity of the iron mold 5; the first box turner 12 can clamp and rotate the iron mold for matching with the box closing machine 13, and the box closing machine 13 can smoothly and accurately finish the box closing actions of the upper iron mold 51 and the lower iron mold 52 of the iron mold 5.
As shown in fig. 1, the pouring section 2 includes a pouring machine 24 provided on one side of the second rail 22 and a pouring trolley 23 provided on the second rail 22; the pouring trolley 23 is used for bearing and transporting the iron mold 5; the casting machine 24 is used for casting molten iron into the iron mold 5 after mold closing. The pouring trolley 23 is used for bearing and transporting the iron mold 5, so that the accurate positioning of the position of the iron mold 5 is realized; the casting machine 24 is used for casting molten iron into the iron mold 5 after the mold closing, and precisely controlling the casting speed by adjusting the gradient of the ladle; the track changing system 25 pushes the pouring trolley 23 to transversely translate so that the pouring trolley 23 and the iron mold 5 transversely move from the first section to the second section of the second track 22, and the box lifting machine 26 is used for conveying the iron mold 5 onto the third track 27 and pushing the pouring trolley 23 to transversely move from the second section to the first section of the second track 22.
As shown in fig. 1, the unpacking and cleaning section 3 includes a unpacking machine 31 disposed on a third track 27, a casting machine 32 is disposed at a rear section of the unpacking machine 31, a second box turning machine 33 is disposed at a rear section of the casting machine 32, a vibration shakeout machine 34 is disposed at a rear section of the second box turning machine 33, and a third box turning machine 35 is disposed at a rear section of the vibration shakeout machine. The box opener 31 can realize mechanical automatic box opening and separation of an upper iron mold 51 and a lower iron mold 52 of the iron mold 5, the casting machine 32 is used for taking out the keel plate 54 from the iron mold 5 to finish casting process, and the vibration shakeout machine 34 uses vibration and impact to separate molding sand in a casting mold from the iron mold 5.
As shown in fig. 3, the control system 4 is provided with a detection system, and the detection system includes a first temperature sensor 41, a second temperature sensor 42, a third temperature sensor 44, a fourth temperature sensor 45, a first timer 43, a second timer 46, and a displacement deformation measuring instrument 47; the first temperature sensor 41 is arranged on a roller way in front of the molding machine 11; the second temperature sensor 42 is installed in the molding machine 11; the third temperature sensor 44 is positioned in front of the pouring trolley 23; the fourth temperature sensor 45 is located above the pouring trolley 23; the first timer 43 is installed in the molding machine 11; the second timer 46 is positioned on the pouring trolley 23 and the box opener 31; the displacement deformation measuring instrument 47 is located on the casting machine 32. The first temperature sensor 41 is used for detecting the temperature of the iron mold 5 before molding, the second temperature sensor 42 is used for detecting the temperature of the metal mold in the molding machine 11, the first timer 43 is used for recording sand curing time, and the iron mold 5 temperature, the metal mold temperature and the curing time influence the strength of the sand shell so as to directly determine the dimensional accuracy of the casting 54; the third temperature sensor 44 is used for detecting the temperature of the iron mold 5 before molten iron pouring, the fourth temperature sensor 45 is used for detecting the temperature of the molten iron, and the temperature of the iron mold before molten iron pouring and the temperature of the molten iron influence the cooling and solidification effects of the molten iron; the second timer 46 is used for recording the pouring time of molten iron and the unpacking time after the pouring is completed, the pouring time reflects the pouring speed, and the unpacking time influences the temperature difference of each part of the rib plate 54 and further influences the final residual stress; the displacement deformation measuring instrument 47 is used for detecting the flatness of the rib plate 54.
The intelligent molding production line of the dragon rib plate can realize intelligent molding of the dragon rib plate, and the intelligent molding production line can realize production through three-section work of a molding section, a pouring section and an unpacking cleaning section, so that the effects of high production efficiency and good production quality are realized.
Example 2: according to the embodiment, on the basis of the intelligent molding production line of the keel plate, an intelligent algorithm is arranged in a control system, wherein the algorithm firstly obtains the relation between technological parameters and the deformation of the keel plate through numerical simulation, secondly establishes a functional model between the technological parameters and the deformation and production efficiency of the keel plate through a neural network, then optimizes by utilizing a genetic algorithm, designs the reverse deformation based on the principle of high efficiency, finally acquires the technological parameters in real time in the production process, and optimizes the unexecuted working procedures in real time. As shown in fig. 4, the specific steps are as follows:
step one: as shown in fig. 5, a molding process model is established by using UG, simulation is performed by using ProCAST based on orthogonal test design, the relation between process parameters and the deformation of the rib plate is obtained, and a formula is usedLogarithmic numberNormalizing the data, wherein x' is normalized data, x is input data, x max Equal to 1, x min Equal to 0. The step can provide a data base for the function model under the condition of no existing data; in addition, aiming at the problem that the influence of small order-of-magnitude parameters on results is too small, the step enables data of different orders to have equal positions through normalization.
Step two: establishing a neural network function model between the technological parameters and the deformation of the rib plates, and training the neural network function model based on a data set; the method specifically comprises the following steps:
the first step: the calculation formula of the basic unit of the neural network is y=f (kx+a);
wherein x is input data, k is weight, a is threshold value, and y is output;
in this embodiment, the activation function is a Sigmoid function, and the formula is:
the activation function enables the neural network to have extremely strong nonlinear mapping capability.
As shown in fig. 6, the number of input layers is designed to be the number of process parameters, the number of output layers is designed to be the number of target parameters, and the number of hidden layer nodes refers to an empirical formula:
wherein n is 1 The number of nodes is the hidden layer, which is equal to 9, n is the number of input layers, which is equal to 9; m is the number of output layers and is equal to 2, and z is a constant which is more than 1 and less than 10;
the formula for combining a single neural network:
B 71 =f(K 79 ×X 91 +A 71 );
Y 21 =f(K′ 27 ×B 71 +A′ 21 );
obtaining a neural network model:
Y 21 =f(K′ 27 ×f(K 79 ×X 91 +A 71 )+A′ 21 );
wherein K is 79 、A 71 、K′ 71 And A' 21 Is an unknown coefficient;
and a second step of: training the neural network function model based on the data set, setting the maximum iteration number as 1000 and setting the maximum training error as 10 -6 The minimum training rate is set to 0.9;
and a third step of: calculation of K by means of gradient descent 79 、A 71 、K′ 71 And A' 21 The specific value is substituted into the formula of the neural network model to finish the establishment of the neural network model.
The step means that a known function model is formed between the technological parameters and the deformation amount and the production efficiency of the rib plates.
Step three: optimizing technological parameters by utilizing a neural network function model and a genetic algorithm, and designing the reverse deformation of the keel plate metal model according to the optimization result, as shown in fig. 7, specifically comprising the following steps:
the first step: setting the number of input parameters as 9, the population size as 100, the iteration times as 100, the maximum value of the individual as 1, the minimum value as 0, and randomly generating the input parameters.
And a second step of: and (3) randomly generating data, and introducing the data into the neural network function model obtained in the step two for calculation, and sequencing according to the advantages and disadvantages of the results, so as to leave the first 50 groups of better results.
And a third step of: randomly and freely combining the process parameter sets corresponding to the 50 groups of the left results to generate 100 groups of process parameter combinations required by the next calculation; the process parameter is shifted to a better direction in the method of superior and inferior elimination.
Fourth step: randomly modifying a plurality of parameters in a plurality of process parameter combinations; the step avoids the optimizing process from falling into a local optimal value in a variant mode.
Fifth step: and (3) continuing to calculate the second step, entering into circulation, judging the obtained result as an optimal result after the circulation times reach 100 times, carrying technological parameters of the optimal result into a function model to predict the deformation of the keel plate, designing the reverse deformation of the keel plate metal model according to the deformation if the requirement is met, and jumping to the first step if the requirement is not met.
Step four: the method comprises the steps of collecting data in real time and optimizing process parameters in real time through an algorithm, and specifically comprises the following steps:
the first step: the data of the executed process is collected in real time through a detection system (namely a temperature sensor, a timer and a displacement deformation measuring instrument). The intelligent algorithm system can acquire the state of the production line in real time in a real-time acquisition mode.
And a second step of: the acquired temperature is continuous data, and discretization is carried out on the continuous data.
And a third step of: and carrying out normalization processing on the discretized data.
Fourth step: and (3) substituting the normalization result of the acquired data for a random value in a genetic algorithm, and transmitting the calculation result to each device. The step can optimize the technological parameters of the non-executed procedure in real time.
Aiming at the problem of low digital level of a metal part forming production line, the embodiment adopts a temperature sensor, a timer and a displacement deformation measuring instrument, and realizes the acquisition of production line data. Aiming at the problems that deformation exists inevitably in the molding process of the keel plates and the deformation is difficult to predict, the method simulates through orthogonal test design, establishes a functional model based on a neural network, determines the functional relation between technological parameters and the deformation and production efficiency of the keel plates, optimizes by utilizing a genetic algorithm, and obtains the optimal technological parameters under the high-efficiency condition and the reverse deformation required under the condition. Aiming at the problem that the production line cannot produce according to the established technological parameters due to external factors in the production line, the method utilizes the data acquired in real time to acquire the result according to the data of the executed process based on a genetic algorithm, so that the production method can design the optimal die structure and technological parameters, can realize the real-time acquisition and real-time control of the technological parameters, can optimize the technological parameters of the unexecuted process in real time according to the condition of the executed process, and can effectively control the quality of products.

Claims (7)

1. An intelligent shaping production line of keel plate, its characterized in that: the production line comprises a modeling section (1), a pouring section (2), an unpacking cleaning section (3), a control system (4) and an iron mold (5); the rear section of the modeling section (1) is provided with a pouring section (2), and the rear section of the pouring section (2) is provided with a box opening cleaning section (3); the molding section (1), the pouring section (2) and the unpacking cleaning section (3) are respectively connected with the control system (4); the iron mold (5) sequentially runs through the molding section (1), the pouring section (2) and the unpacking cleaning section (3); the iron mold (5) is used for casting molding of the keel plate.
2. The intelligent molding production line of the keel plate according to claim 1, wherein: the molding section (1) comprises a first track (21), a molding machine (11) is arranged on the first track (21), a first box overturning machine (12) is arranged at the rear section of the molding machine (11), and a box closing machine (13) is arranged at the rear end of the first box overturning machine (12).
3. The intelligent molding production line of the keel plate according to claim 2, wherein: the pouring section (2) comprises a second rail (22), and a pouring machine (24) and a pouring trolley (23) arranged on the second rail (22) are arranged on one side of the second rail (22); the pouring trolley (23) is used for bearing and transporting the iron mold (5); the casting machine (24) is used for casting molten iron into the iron mold (5) after the mold closing.
4. The intelligent molding production line of the keel plate according to claim 3, wherein: the unpacking and cleaning section (3) comprises a third track (27), a unpacking machine (31) is arranged on the third track (27), a casting machine (32) is arranged at the rear section of the unpacking machine (31), a second box turning machine (33) is arranged at the rear section of the casting machine (32), a vibration shakeout machine (34) is arranged at the rear section of the second box turning machine (33), and a third box turning machine (35) is arranged at the rear section of the vibration shakeout machine.
5. The intelligent molding production line of the keel plate according to claim 4, wherein: the first track (21) is parallel to a third track (27); the second track (22) is provided with two parallel sections, the first section is connected with the rear end of the first track (21), the second section is connected with the front end of the third track (27), and the rear end of the first section is connected with the front end of the second section through a track transfer system (25); and a suitcase machine (26) is arranged at the joint of the second track (22) and the first track (21) and at the joint of the second track (22) and the third track (27).
6. The intelligent molding production line of the keel plate according to claim 4, wherein: the control system (4) is internally provided with a detection system, and the detection system comprises a first temperature sensor (41), a second temperature sensor (42), a third temperature sensor (44), a fourth temperature sensor (45), a first timer (43), a second timer (46) and a displacement deformation measuring instrument (47); the first temperature sensor (41) is arranged on a roller way in front of the molding machine (11); the second temperature sensor (42) is arranged in the molding machine (11); the third temperature sensor (44) is positioned in front of the pouring trolley (23); the fourth temperature sensor (45) is positioned above the pouring trolley (23); the first timer (43) is arranged in the molding machine (11); the second timer (46) is positioned on the pouring trolley (23) and the box opening machine (31); the displacement deformation measuring instrument (47) is positioned on the casting machine (32).
7. The intelligent molding production line of the keel plate according to claim 1, wherein: the iron mold (5) comprises an upper iron mold (51) and a lower iron mold (52); the surfaces of the die cavities of the upper iron die (51) and the lower iron die (52) are covered with a sand covering layer (53), and the surfaces of the sand covering layer (53) and the shape of a metal model of the keel plate in the molding machine (11) are kept consistent and are provided with reverse deformation.
CN202320990840.1U 2023-04-27 2023-04-27 Intelligent molding production line of dragon rib plate Active CN219881304U (en)

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Application Number Priority Date Filing Date Title
CN202320990840.1U CN219881304U (en) 2023-04-27 2023-04-27 Intelligent molding production line of dragon rib plate

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CN202320990840.1U CN219881304U (en) 2023-04-27 2023-04-27 Intelligent molding production line of dragon rib plate

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Publication Number Publication Date
CN219881304U true CN219881304U (en) 2023-10-24

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