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Sand cast aluminum or steel, the flat baseplate that forms the floor of the projector’s interior cavity supports the entire unit.


for example, the baseplates that support units weighing as much as a 280 lbs.—are sand cast in either stainless steel or aluminum. Casting these components reduces cost versus high-precision welding and machining. Compared to those machined from stock, the cast metal components offer improved mechanical and physical properties at a reduced cost.


Within the projectors, a number of components must meet high standards for form, fit and functionality. Te lens mount, for example, could produce myriad technical prob- lems if it did not meet exact standards. “High precision is essential to the function of Christie’s


projectors,” said David Kiers, director of engineering at Christie. “Critical features are machined after casting to hold tighter tolerances when required.” Many other applications, such as those related to the


projector’s processors and microchips, require much smaller components with significantly different design consider- ations. In addition to aluminum, steel and magnesium, zinc is used for applications with lower weight considerations. In total, Christie uses components produced via diecast-


ing, permanent mold, sand and investment casting processes. When identifying a possible candidate for conversion to a casting process (or redesigning an existing casting), the selected process is based upon many factors including cost, expected volumes, choice of materials, degree of complexity, visual cosmetics and final appearance. Engineering must overcome two traditional barriers


to develop a conceptual design to obtain a cost-effective, feasible casting. The first challenge is developing a rela- tionship with metal casting suppliers that encourages and


铝合金或铸钢的砂型铸件,构成投影装置的内部空腔的底 板支撑整个装置。


多种材质和不同的工艺制造。较大的零部件,例如重达 127Kg的支撑装置的底板,是不锈钢或铝合金砂型铸 件。与采用高精密焊接和机加工工艺相比,这些零部件 采用铸造工艺降低了成本。与从坯料直接加工相比,铸 造的金属零部件在降低的成本同时,还能够改进力学性 能和物理性能。


投影装置的内部,许多组件都必须满足外形尺寸、配 合和功能等方面的高要求。例如镜头固定件,如果它不 符合确切的标准,会产生无数的技术问题。 “高精度是Christie投影装置的重要功,”Christie 公司工程部总监大卫•基尔说,“如有要求,就要铸造 后加工,以保持更严格的公差。”


许多其它应用,如与投影机的处理器和微芯片有关 的,这些小得多的组件需要考虑特别不同的设计因素。 除铝合金,钢和镁之外,也采用锌合金。 总体而言,Christie公司使用压铸用的某种金属型铸 造,砂型铸造,熔模铸造等工艺生产的铸件。在确认以 某种可能的候选工艺替代现行的铸造工艺时(或重新设 计现有的铸造工艺),选择工艺基于许多因素,包括成 本、预期产量、选用的材质、复杂程度、视觉美观和最 终外观。


工程师在开发概念设计,以期生产出具有成本效益且 54 | FOUNDRY-PLANET.COM | MODERN CASTING | CHINA FOUNDRY ASSOCIATION June 2015


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