SUPPLIER’S PERSPECTIVE/供应商观点
Focus More on Casting Cleaning, Gain More on Efficiency
细节决定成败 ——关注铸件清理工序的节能减排和降本增效 In China, the time of cheap labor has gone. The
average wage of workers has been growing at 14% each year and doubled every five years since China’s economic reform started 30 years ago. Foundries face great pres- sure due to the growing labor cost, as it becomes more difficult to recruit employees. Heavy pollution, poor working environment and high
work intensity contribute to recruitment difficulties in China because people’s idea about life and working is changing. With a booming industry and fierce competi- tion, customers have a higher demand for casting quality, lower cost, and efficiency, which brings more attention to casting cleaning as the last important procedure of the whole production. Shot blasting is a key process of casting cleaning
which refers to abrasive media removing the sand, scale and contaminants to achieve a bright and clean casting surface by hitting the casting through centrifugal wheel force or compressed air. This process play an important role in production cost and efficiency. Under the increasingly fierce competitive environ-
ments, metalcasting businesses should pay more at- tention to cost reduction in every production process. Beyond concentrating on the main commodities and key processes, including raw material, molding, finished products etc., metalcasters also should pay attention to the control of casting cleaning. According to TAA Metal Technology Co., Ltd., Shangdong, China, choos- ing high-performance abrasives is the easiest access for reducing the casting cleaning cost. TAA Metal also has observed that today’s foundry enterprises in China have changed how they purchase abrasives. Where before they were only concerned with comparing price, now they compare cost, performance rate and technical sup- port ability. This change will accelerate the application technology of casting cleaning and the technical im- provements of the metal abrasives industry, accordingly, which will better help foundry enterprises achieve cost reduction. Shot blasting is an effective way for casting enterpris-
es to reduce cost and improve efficiency. The following aspects are important to this process: 1. Shot blasting speed: For abrasives at the same size,
廉价劳动力时代一去不复返。改革开放30年来，在岗 职工平均工资以。年均14%的水平在增长，工资五年翻 一番，铸造企业的劳动力成本持续加大，企业经营压力增 大。招工难、招聘难。从南方到北方，很多铸造企业人 力匮乏，厂门口常年挂有招工的牌子。这种状况5年前没 有。
造成以上现状的原因很多，比如：污染多、环境差，工 作强度大等等，人们的生活、工作观念正在变化，作业环 境的改善和自动化程度的提高怎样才能适应人们的需求？ 随着铸造业的蓬勃发展和竞争的加剧，人们对铸件的质 量、成本、生产效率等方面的要求也越来越高，铸件清理 作为铸件生产的重要后加工工序，关系着铸件的最终表面 质量、生产效率及铸件的成本，因此也越来越受到人们的 关注。
抛丸清理是铸件清理的关键工序，是指通过抛丸机高速 运转的叶轮产生的离心力或通过压缩空气，将磨料抛打到 铸件上，对铸件表面进行连续不断的敲击，清除粘砂、氧 化皮和其他污物，使铸件获得光整、清洁的表面，这一工 序虽然不像熔炼、造型、浇注等工序对铸件质量有根本性 的影响，但清理工序控制的好坏对铸件的生产成本和生产 效率也起着至关重要的作用。
针对这一应用趋势，为了更好的帮助铸造企业达到 降本增效的目的，我们
成功研制了新型高性能磨料——低贝混合磨料。 除了对磨料质量的控制，对抛丸工艺的合理运用也是铸 造企业降本增效的有效途径，以下几个方面需特别注意： 1. 抛丸速度：磨料在运行中产生的动能可以用
E=1/2MV2计算，相同粒度的磨料，抛射速度越高，对 铸件的抛射力度越大，清理能力越强，得到的表面粗糙 度也越大，适当的抛丸速度才能获得理想的清理效果和 表面质量。 2. 抛丸时间：铸件抛丸的时间由多个因素决定，包 括铸件的结构、表面状况、抛丸机器的状态及磨料的性 能，在能达到表面质量的前提下，抛丸时间应尽可能短 一些，以保证更高的清理效率。 3. 抛丸设备状态：抛丸设备运行的状态是否良好 是影响清理成本和效率很重要的因素之一，包括抛头抛 射的角度、丸砂分离器状态、易损件的完好程度等，因
September 2014
FOUNDRY-PLANET.COM | MODERN CASTING | CHINA FOUNDRY ASSOCIATION | 77
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