Matching relationship between insulation furnace capacity and wheel hub mold production capacity

Matching relationship between insulation furnace capacity and wheel hub mold production capacity
The capacity of the insulation furnace is configured based on 2-3 hours of aluminum consumption. A smaller capacity can cause liquid level fluctuations and unstable filling pressure, while a larger capacity can increase insulation energy consumption and burn damage.
Calculate the hourly aluminum consumption first
The hourly aluminum consumption is equal to the weight of a single piece multiplied by the modulus per hour. Single piece 14kg, single mode for 10 minutes, 6 molds per hour, aluminum consumption of approximately 84kg.
Adding the loss of sprues and waste products, the actual aluminum consumption needs to be multiplied by a coefficient of 1.15-1.25. The actual weight of the above example is about 97-105kg.
This number determines the basic capacity of the furnace and also determines the feeding frequency.
Reasonable range of capacity
The furnace capacity is usually taken as 2-3 hours of aluminum consumption. Calculated at 100kg/hour, a capacity of 200-300kg is more suitable.
Less than 2 hours, the liquid level drops rapidly, and changes in static pressure head affect the filling process. Frequent addition of materials results in significant temperature fluctuations in the aluminum liquid.
Above 4 hours, the aluminum liquid stays in the furnace for too long, leading to increased suction and burning. The energy consumption for insulation has also increased accordingly.
The influence of liquid level on filling pressure
Low pressure casting relies on the air pressure inside the furnace to press aluminum liquid into the mold cavity through the riser. The liquid level decreases and the required pressure increases.
For every 100mm decrease in liquid level, the static pressure head decreases by approximately 2.6kPa. For a filling pressure of 0.02-0.08MPa, the proportion can reach 3% -13%.
The recommended precision for liquid level control is within ± 20mm. It is not realistic to rely on manual observation, and liquid level detection and automatic feeding should be equipped.
Furnace lining and temperature control
The lining material affects the lifespan and energy consumption. When the pouring temperature is 680-720 ℃, the thickness of the furnace lining is usually taken as 80-120mm.
It is recommended to control the uniformity of furnace temperature within ± 10 ℃. Exceeding the tolerance will cause local overheating of the aluminum liquid and increase the suction volume.
Xinfeng Mold will remind customers to check the effective volume of the furnace in the supporting suggestions, rather than just looking at the nameplate capacity. The effective volume is usually only 70% -80% of the nameplate.
Selection of feeding method
Artificial feeding is suitable for small batches, with high labor intensity and significant liquid level fluctuations.
Automatic feeding and liquid level feedback can stabilize the liquid level at ± 10mm. It costs about 80000 to 200000 yuan and can be recovered within two years.
The mode of centralized melting and transfer package is suitable for multi machine workshops. The quality of aluminum liquid is more stable, but the transportation process will cool down by 15-30 ℃.
Common Misconceptions
Misconception one is to choose the furnace based on the largest piece. We only make a few large items throughout the year, but we are equipped with a large furnace, resulting in wasted energy consumption for daily insulation.
The second misconception is to ignore the effective volume. A furnace with a nameplate of 500kg may only be available for 380kg in actual use.
The third misconception is that adding ingredients does not depend on temperature. Excessive input of cold material at once can cause a sudden drop in the temperature of the aluminum liquid, which may result in cold insulation in the mold.
How to verify if the match is reasonable
Continuous production for 4 hours, record the changes in liquid level and filling pressure. Frequent activation of pressure compensation indicates a small capacity.
Observe the distribution of scrap rates over time periods. After feeding, the scrap rate of the first mold is obviously high, indicating that the temperature or liquid level recovery is insufficient.
Xinfeng Mold will attach a matching suggestion between furnace capacity and cycle time when delivering the wheel hub mold, for customers to review the existing configuration.
Frequently Asked Questions
Question: How is the capacity of the insulation furnace calculated?
Answer: Multiply the aluminum consumption by a factor of 1.15-1.25 for 2-3 hours.
Q: What are the problems with a small capacity?
Answer: The liquid level fluctuates greatly, the filling pressure is unstable, and the feeding is frequent.
Q: What is the cost of having a large capacity?
Answer: The insulation energy consumption is high, and the suction and burning of aluminum liquid increase.
Question: What is the precision of liquid level control?
Answer: It is recommended to use automatic feeding within ± 20mm.
Q: What is the difference between the effective volume and the nameplate?
Answer: The effective volume is usually 70% -80% of the nameplate.
Q: Is it normal for the scrap rate to be high after adding materials?
Answer: Abnormal, indicating insufficient temperature or liquid level recovery.
Recommended search keywords
Insulation furnace capacity, low-pressure casting insulation furnace, wheel hub mold supporting equipment, aluminum liquid level control, wheel hub mold manufacturer, low-pressure casting mold, automatic feeding system, casting equipment matching, melting furnace selection, casting mold manufacturer