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Experience from professional manufacturers in quality management of copper casting sand

release time:2024-05-20    This article was read :49 次

Why can the quality of green sand copper castings reach such a high level?

My factory's sand processing equipment is Japan's Shinto automatic sand recycling system. For equipment, it must be ensured to perform its functions; Using this device, the performance (functionality) of many devices decreases; Seriously no longer functioning; Restoring and maintaining its functionality is crucial, ignoring its "chaos". Our company adopts the "TPM" full staff guarantee method; Site personnel, equipment security personnel, and technical personnel participate in the overall security, equipment inspection, 001775 routine maintenance, regular maintenance, spare parts, and other departments are responsible for. Each department has the responsibility to ensure the functionality of the equipment and improve the start-up rate of the equipment.

The functions of our sand processing equipment are:

(1) Magnetic separation:

 Selecting copper, copper beans, and other copper substances from the recovered sand is a necessary step to ensure "pure" sand;

(2) Primary crushing and screening: 

crushing large sand blocks and screening;

(3) Sand cooling and screening: 

Automatically measure the temperature of the recovered sand, water cooling water content, dust removal, and exhaust gas, thereby reducing the temperature of the recovered sand;

(4) Premixed materials and storage: 

add a certain amount of bentonite, pulverized coal, dust, water (sand temperature, automatic measurement of moisture) and other premixed materials in advance for storage;

(5) Final mixing: 

add a certain amount of bentonite, pulverized coal, dust, and water for mixing, and automatically measure the water, sand temperature, and CB value. Set the CB value, and control it. Only sand can be discharged if the CB value is within the acceptable range; When the sand is discharged, certain sand samples are taken for sand performance testing (sand test).

(6) Transportation: 

Transport qualified sand belt conveyors to the molding line for molding.

Only when each equipment can guarantee the expected function can qualified molding sand be produced. Qualified molding sand is the first and key step to ensure the surface quality of castings.


Material:

Wet sand material:

Green sand: Our company uses Dalin sand in Inner Mongolia, with a particle size of 50-100;


Bentonite: Our company uses red volcanic bentonite;


Pulverized coal: Pingdingshan pulverized coal is used;


Experience: Don't try to be cheap and use raw materials that cannot be guaranteed in quality, otherwise the loss of casting waste will save several times or even tens of times in raw materials.

copper casting

Management:

(1) Equipment management: 

the lubrication inspection of the sand mixer was indeed carried out; The cleaning of grinding wheels, the height of the scraper blade, and the distance are directly related to the performance of sand mixing; The effect of restoring the magnetic separation of sand is; The effect of sand is cooling (sand temperature); The effect of dust removal equipment and whether the dust emission is controllable; Measuring equipment such as automatic bentonite, measuring pulverized coal, measuring sand content, and adding water should be regularly checked to ensure authenticity. Ensure the stability and stability of each device. Guaranteed and effective.

(2) Sand performance management:

The final mixing control system performs online detection of each CB value, moisture, sand temperature, and other items, and controls sand mixing time, automatic sand discharge, etc; The performance testing of sand is usually carried out by the production line operator to detect the CB value (strictly practical), and the monitoring of conventional items such as moisture, compressive strength, and gas permeability is carried out at a frequency of several times per grinding; Not only do the production line personnel understand the quality of the "products" produced by the production line, but also the production line personnel themselves ensure the quality of the "products" and implement sand mixing setting adjustments; In the laboratory, quality personnel monitor the effective clay content (adsorption method), combustion amount, mud content, and sand particle size distribution (average fineness AFS) 1-2 times a day; Visually observe the final overall results at the production site and instruct on-site personnel to adjust the sand.

(3) Adjust sand properties:

To monitor sand performance, use the upper and lower limit management tables for trend management. If the limit is exceeded or the trend is not good, timely adjustments are needed to prevent adverse events. In addition, the relevant departments must be contacted. In addition, it is necessary to master the changes in molding sand performance from the mixer side to the molding side.

(4) Casting quality analysis and countermeasures:

It is necessary to analyze defective products in castings. What is the cause of the defect, the classification is different, the existing material, the separation is a sand problem, or a mold problem, tooling problem, equipment problem, copper water problem, so countermeasures must be taken to confirm the adverse impact of the defective blank (quality angle, defective product display rack), and we must confirm the countermeasures and implementation measures; Confirm the effectiveness of implementation measures and determine the next step; And use PDCA's working methods to promote continuous quality improvement.

(5) Raw material management:

The quality of raw and auxiliary materials must be managed. It is directly related to the quality of the casting; Raw and auxiliary materials must be qualified (reported by the supplier), and if necessary, raw and auxiliary materials should be tested at the factory. Can be used. Regularly inspect the raw and auxiliary material manufacturers for engineering inspection, confirm that the manufacturers can produce products that meet the requirements, and propose improvement suggestions to the raw and auxiliary material manufacturers.

(6) Standard Operating Instructions: 

Refers to instructions that specify the sequence of work, as well as the quality of safety and other considerations in each step. Anyone who works according to the same standards should carry out work to ensure quality and safety. At the same time, it is used for the education of new immigrants. Tools. Standard work instructions are not static and can be improved, but after improvement, everyone must comply with them.

(7) Continuous improvement:

Improve endlessly, constantly pursue high goals; "Where there is something bad (in any aspect), we must find ways to improve it so as to promote development in all aspects.".

(8) Master the change points:

During the production process, various conditions are changing, and it is necessary to grasp the change points; If the personnel are changed to,, and the setting conditions of the equipment change, when the change point occurs, the frequency of quality inspection and other items should be strengthened to ensure the same quality and prevent batch failures. happen.

(9) Tips for creative kungfu:

Creative Kung Fu, creativity, good ideas, achieved through practice, and achieved results, whether it's cost, safety, quality, low workload, environment, low inventory deductions, standardization, etc. As long as it's good, you can encourage everyone to implement it, and you must give some rewards.

(10) Practice of the Quality Control Activity Group:

Each team spontaneously establishes a QC activity group, sets up projects, formulates plans, conducts regular activities, overcomes problems, summarizes results, and publishes the results; The company has given certain rewards to the activities of the QC team, and excellent QC team topics are published in China or by TMC in Japan.

Environmental Science:

Working temperature, humidity, workshop lighting, noise, pollution (dust content), hygiene, etc. Modern foundries and cleaner production have completely changed the face of former foundries, enabling workers to work in a comfortable environment. (Aluminum alloy die casting and low casting workshops are already fully air-conditioned closed workshops similar to mechanical workshops.). The dust removal equipment in the foundry determines the dust pollution in the workshop, which indirectly affects the dust removal effect of sand treatment; Good dust removal equipment can control the dust content in the sand (determine the amount of mud), thereby controlling the permeability of the sand. Directly related to the quality of castings.

The working environment can affect people's emotions, and a highly polluting working environment will not motivate operators to improve quality.


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