Centrifugal Casting Machine for Powerplant

What is Centrifugal Casting?
Centrifugal casting is a process that delivers castings of very high material soundness, and thus is the technology of choice for applications likejet engine compressor cases,petrochemical furnace tubes, manymilitary products, and other high-reliability applications.
In the centrifugal casting process, molten metal is poured into a spinning die. The die can be spinning either on a vertical or horizontal axis depending on the configuration of the desired part. Ring and cylinder type shapes are cast vertically; tubular shapes are made with the horizontal centrifugal process. Either process may be used to produce multiple parts from a singlecasting.External structures and shaping can be cast in place to significantly reduce post-processing including machining orfabrication.
Because of the high g-forces applied to the molten metal in the spinning die, less dense material, including impurities, "floats" to the I.D. where it is subsequently removed by machining. Solidification is managed directionally under pressure, from the O.D. to the I.D., avoiding any mid-wall shrinkage, leaving a defect-free structure without cavities or gas pockets.
8 station centrifugal casting machine for cylinder liner is composed of the multi-station engines and a auxiliary engine. 8 main engines areevenlydistributed on the rotary roundtable.The main engine is rotated to different positions by the rotary round table.Four sets of auxiliary engines is distributed around the rotary round table fixedly.When main engine is rotated to correspondingposition,each auxiliary engine will completerespectivefunction to main engine with cleaning mold ,spraying coating,pouring and extracting the casting.
The main engine's speed is adjustable and steady in the high speed.The Spraying process is very advanced of multistage velocity control. The key process parameters are real-time monitor and adjusted by automatic control system. So it can ensure the casting process parameters repetition andconsistency. It eliminates the influence of artificial factors to the casting process parameters. So it ensures stable quality of the casings.
Feature
The 8-station rotating-plate-type centrifugal casting machine is composed of rotating platform, cantilever-type centrifugal casting main engine, automaticcleaning device, automatic painting device, automatic pouring device, cast tube crosswise device and mould cooling system.
main engine
The cantilever-type centrifugal casting machine is the core of the complete machine. 8 cantilever-type centrifugal casting machines are distributed uniformly in the rotating working platforms. The variable frequency motor drives the main shaft through belt transmission structure to realize the rotation of the mould and the centrifugal pouring of the casting. The mould is installed in the subpanel and the main shaft rotating speed could realize stepless speed regulating, which would meet the process requirements of casting of different diameters.
In order to make the mould stop quickly, the cantilever-type centrifugal casting machine is equipped with a brakingdevice, which would reduce the working pace of the machine andimprove working efficiency.
Each centrifugal casting machine is equipped with safety protection cover to realize the safetyproduction of the casting.Rotary round table
Rotary table is the keypart of the eight-station rotary table type centrifugal casting machine which can achieve the multiple-station working requirements of centrifugal casting machine. The rotation of the table is achieved throughthe gear driving mechanism to drive the rotary support relying on the servo motor, and the entire rotary motion is precisely positioned by the servo control. The rotary table rotates intermittently and pauses at every rotation of 45 degrees, and each station completes its corresponding motion, and it will re-rotate to the next station after all stations complete the work. The rotary table rotates in a circle in which it completesthe centrifugal casting process of one cast. The rotaryspeed can be set according to the process requirement of each station, and be precisely controlled.Cleaning system
The automatic cleaning device can realize the cleaning by generalmotor drives the cleaning car moving through a chain drive mechanism. The motor drives the cleaning brush to rotate through the synchronous belt to achieve the purpose of cleaning the inner walls of the mold by the reciprocating movement and rotation of the cleaning brush atthe cleaning. The mold is atthe state of brake lock close atcleaning to prevent the mold rotating with the cleaning brush. After cleaning, the end cover is installed bymanual.Spray coating
The automatic spraying devicecan realize the accurate movement of the spraying car through the servo electriccylinder unit. Sprayingwork for the cavity of the whole mold can be achieved relying on the automatic travelling ofthe spraying rod and the mold rotates to meet the requirement of the production process. The travelling speed of spraying car is adjustable in the range of 0 ~ 1,000mm/s.
Tool for casting extraction
Casting extraction mechanism is controlled by servo and Pneumatic control system. So it is very accurate and reliable.It can extract the casting smoothly from the tube molds. The position and speed of the casting extraction can be set up and adjusted.
Pouring system
The automatic pouring device mainly consists of pouring ladle, automatic weighing unit (with the accuracy of 100g, reaction time less than 0.2s), pouring ladle tilting device, pouring basin, traveling car and etc. The weight of metal liquid which will be filled into the pouring ladle is detected by the automaticweighing unit and will be displayed on the large screen. The filling of liquid will stop when the metal liquid in the pouring ladle reaches the set weight. When pouringcar travels to the position for pouring, the variable frequency motor will drive the pouring ladle to tilt to pour the metal liquid into the pouring mold through the pouring basin. Pouringcar travels backward to the position of molten iron for the next centrifugal casting after the previous pouring is completed. The tilting rate of the pouring ladle can be adjustableaccording to the requirement of the procedure.Electric control system
Control system use PLC as the control core and use the man-machine interface as the monitoring system.It controls the whole process automaticallyand monitors the whole production process.Control system has the perfect protective measures, such as over-current protection, over-load protection, etc. The process parameters of the main engine and the auxiliary engine all can be adjusted and stored in the man-machine interface such as work positions and velocity. It meets the production process requirement of a variety of cylinder liner castings in a certain range.End cover and casting unloading device
The two motionsof unloading endcover and casting are completed on the unloading station. The working process is as follows: after the rotary table rotates to the ready place, and the mold stops rotating and brake locking, the end cover is unloaded by manual, and the unloading car will travel forward and the unloading claw reaches the unloading station, and the clamp distracts with the driving of tension cylinder and catches the inner wall of the cast, then, the unloading car will back off to pull out the cast and end cover onto the support of the cast, and loosen the clamp, and the unloading car backs off and leaves the cast on the tray, and the turnover mechanism will turnover onto the conveying unit of the cast (self-prepared).
The castings produced by our machine
Main technical parametersSerial numberNameofparameterParameter valuesUnit1Turntable diameter2500mm2Number of station83Rotation power of motor4Kw4Mold rotation diameterΦ420mm5Casting maximum diameterΦ120mm6Casting maximum length300-600mm7Speed of mold0~1600rpm8Main enginepower of motor5.5Kw9Centre-to-centre spacing between the ground and mold1000mm10Total power of the machine55Kw