continuously improved its pattern machine production, and it successfully developed electronically-controlled, pressure-feeding and multi-feed gun semi-automatic pattern machines. In 2005, the company developed semi- automatic and full-automatic pattern machines. Now, it has formed a series of domestic pattern machines to meet different needs. Te Beijing Tianzhe Co., has cooperated with


Tsinghua Univ. to successfully develop automatic pat- tern bonding machines. Tese machines, with improved accuracy and efficiency, have been used successfully by the Shaanxi Fast Co. Vibration tables are critical for the EPC process.


Trough more than 20 years of continuous exploration and research, the tables have been improved from one- dimensional vibration tables, two-dimensional vibration tables, three-dimensional vibration tables, frequency-adjust- ment three-dimensional vibration tables and frequency- adjustment three-dimensional PLC automatic controlled vibration tables to today’s vertical circular motion vibra- tion tables. Tese tables, developed by the Beijing Tianzhe Co., have been used on the production line of the Shaanxi Huaen Mechanical Manufacturing Co. Ltd., Shaanxi, China, Shaanxi Fast Co. and Baoding Wade Automotive Castings Co., Hebei, China. In the modern Chinese casting industry, the EPC pro-


cess has four modes of production: • Single production: 1,000 tons per year or less. • Simple production: 1,000-3,000 tons per year. • Semi-automatic production: 3,000-10,000 tons per year. • Semi-automatic and full-automatic production: more than 10,000 tons per year. Unlike many foreign pro- duction lines, the majority of these facilities use some manual assistance. These foundries include Shaanxi Fast Group, Shanxi Huaen Group, Shandong Wanshou Co., Anhui Tongling Wanxiang Co., Hebei Tangshan Chengqi Co. and Inner Mongolia Zhonghuan Co. Te Changchun First Automobile Manufactory, Shanxi


Huaen Machinery Manufacturing, Hefei Casting and Forging, Anhui Quanjiao Diesel Engine and Shaanxi Fast Group have introduced single EPC machines, including primary equipment and casting lines. Two types of foundries are engaged in the production of


large lost foam castings in China: 1. FMC facilities producing automobile die and


machine tool beds, etc., including Dongfeng Motor General Casting Co., Baicheng Tianqi Foundry Co., Tianjin Jingbo Casting Co., Botou Dongjian Casting Co., Shandong Yantai Casting Co. 2. EPC facilities producing automobile dies, includ- ing Botou Qingfeng Machinery, Baicheng Tianqi Foundry Co. Since the first lost foam casting plant was built in China,


more than 200 different kinds of production lines have emerged in 30 years. ■


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3.1 模样制造关键设备


在中实委帮助下，杭州富阳江南轻工包装机械厂于2000 年研制成功第3代间歇式预发泡机。可预发EPS、STMMA 和EPMMA三种材料；预发珠粒均匀；珠粒熟化时间缩 短；预发密度易控制，质量高。2005年又研制成功PLC 控制全自动间歇式预发泡机，预发珠粒密度控制更准确。 在开发预发机同时，对成型机不断改进，先后研制成功 电控成型机，加压加料成型机、多加料枪半自动成型机 等。2005年研发成功半自动和全自动成型机。如今已形成 能满足不同需求的各种规格型号的系列化国产成型机。北 京天哲公司与清华大学合作研发成功自动模样粘接机，已 成功用于陕西法士特公司，精度和效率大大提高。 3.2 铸件造型浇注关键设备 3.2.1 振动台


造型用振动台是消失模铸造中的关键专用设备。20多年 来，经消失模铸造工作者的不断探索、研究和改进提高， 从单维振动台→双维振动台→三维振动台→调频三维振动 台→调频三维PLC自动控制振动台，发展到垂直园周运动 振动台。2005年北京天哲消失模铸造技术有限公司开发成 功垂直园周运动振动台，现已用在山西华恩机械制造有限 公司万吨生产线、陕西法士特集团铸造公司和保定维德汽 车铸件公司的消失模铸造生产线上，取得良好的效果。 3.2.2 造型-浇注流水线


目前我国消失模铸造造型浇注工艺过程主要有以下 四种生产模式：（1）单机生产：生产规模1 000t/年以 下；（2）简易生产线：生产规模1 000~3 000t/年； （3）半自动生产线：生产规模3 000t/年、5 000t/年和 10 000t/年；（4）半自动和全自动生产线，这类生产线 与国外生产线相比，有部分操作工位采用人工辅助，生 产规模在10 000t/年以上：陕西法士特集团、山西华恩 集团、山东万寿公司、安徽铜陵万象公司、河北唐山丞 起公司、内蒙众环公司等。


3.2.3 引进国外消失模铸造设备的厂点 先后有长春第一汽车制造厂、山西华恩机械制造有限 公司、合肥铸锻厂、安徽全椒柴油机厂和陕西法士特集 团公司等企业引进单机、主要设备和铸造生产线，其中5 家整套引进了消失模铸造生产线。 3.2.4 大型铸件的实型铸造和消失模铸造 生产大型铸件的企业有两类：（1）采用实型铸造工 艺，主要生产汽车模具、机床床身等：东风汽车通用铸 锻、白城天奇铸造、天津京泊模具铸造、泊头东建铸造、 山东烟台众达铸造等。（2）采用消失模铸造工艺，主要生 产汽车模具：泊头青峰机械、白城天奇铸造等。 自我国第一条消失模铸造生产线建成30年来，我国消失 模铸造共有200多条不同形式的生产线，通过不断探索、 实践和“优胜劣汰”的考验，逐步发展形成这样的生产格 局：单机→简易线→闭环刚性生产线→开放柔性生产线→ 半开放生产线→半自动生产线→全自动生产线。■


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40 | FOUNDRY-PLANET.COM | MODERN CASTING | CHINA FOUNDRY ASSOCIATION Spring 2012


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