Application Cases of Rapid Sand Casting/Manufacturers of Rapid Sand Casting Equipment/Rapid Sand Casting

Application Cases of Rapid Sand Casting/Manufacturers of Rapid Sand Casting Equipment/Rapid Sand Casting

Application Cases of Rapid Sand Casting/Manufacturers of Rapid Sand Casting Equipment/Rapid Sand Casting

Figure 5: Rapid sand casting process flow

Rapid sand casting Rapid casting exhaust pipe: Figure 6 shows a laser sintered exhaust pipe sand core and lower mold, with a sintering time of 48 hours for the entire sand mold. The sintered sand mold and sand core can be directly poured after aging and combination. (b) For the finished exhaust pipe casting, the material is ductile iron, with a wall thickness of only 5mm at the thinnest point. The time required from design completion to final casting is only one week.

Figure 6: Bottom mold sand mold and sand core of exhaust pipe made by laser sintering


Figure 7: Exhaust pipe ductile iron casting

Rapid sand casting [Case 2]Rapid manufacturing of engine cylinder heads: The internal structure of engine cylinder heads is extremely complex, but the biggest advantage of laser sintering molding is that it is independent of complexity, and the more complex the parts are, the more suitable they are for rapid prototyping production. Due to the complex internal structure and relatively thick wall thickness of the cylinder head, the method for producing these parts is rapid sand casting.
Figure 8 shows an aluminum casting of an engine cylinder head obtained by selective laser sintering sand casting; Figure 9 shows the composite core of the cylinder head air passage and water jacket, which was sintered in one go using laser sintering technology to improve the molding accuracy, with a molding time of only 19 hours. The cylinder head outer mold can be made using traditional methods, which greatly shortens the development time of the cylinder head. From CAD design to cylinder head casting, the completion of Figure 9 only takes about 20 days. Our company has rapidly manufactured 6 pieces for a certain enterprise, which are used for ignition testing and parameter calibration. Due to the close similarity between the casting process and the final production process, the dimensional accuracy and mechanical properties of the parts are highly comparable to those of the final product parts. Therefore, cylinder heads produced by rapid sand casting can be directly used for various evaluation tests of engines, such as flow analysis of air passages and cooling performance testing of water passages. According to different testing needs, several different engines can be simultaneously produced for performance testing.

Figure 8: Aluminum casting of engine cylinder head


Figure 9: Engine cylinder head air passage, water jacket combination core

Rapid sand casting Small batch rapid core making: As shown in Figure 10, it is the valve core of a hydraulic valve in a certain project. A certain casting company received an order for this project. Due to the tight schedule, complex core structure, and long mold opening cycle, the company chose to cooperate with Longyuan Forming and use laser sintering to complete the production tasks of the project in two batches. *Batch completed 10 sets in 5 working days, and the second batch completed 20 sets in 10 working days. Due to the saving of mold making time, the project schedule and progress were ensured.

Figure 10: Hydraulic valve core