The resin sand casting production line has become a popular choice for many domestic foundry companies since June 9th, as it significantly improves product quality. To enhance the surface finish of castings, water-based graphite coatings are commonly used in resin sand molding and graphite coating production lines. These coatings are applied to the surface of the sand molds and then dried using a surface drying furnace. The primary function of this furnace is to dry only the surface layer of the sand without heating the entire workpiece, thus minimizing internal temperature rise and saving energy.
Within the working area, the temperature difference remains within ±3°C, ensuring uniform heat distribution. The furnace temperature is carefully controlled along the enclosure’s temperature, with a tolerance of ±5°C. This prevents overheating of the sand, which could weaken the mold structure. There are two main types of sand drying furnaces: chamber-type and pass-through type. Depending on the fuel used—such as gas or fuel—the shutdown process requires thorough cleaning of the molten iron and residue from the furnace mouth and lining to maintain efficiency.
A large axial fan is used to blow cold air down the side of the furnace wall and exhaust hot air through the taphole, preventing oxidation and reducing cracks in the lining. This helps extend the life of the furnace lining. The cast iron trough of the inverter furnace is constructed using refractory castables, offering long service life and minimal maintenance. With continuous improvements in the shutdown process, the lining can be used over 260 times, while the castable lining lasts more than one heat cycle.
In terms of design, the electric furnace’s internal water system uses copper or stainless steel pipes to ensure high-quality water flow. After installation, the water channels must be thoroughly cleaned. Before the first use of the electric furnace, a low-temperature drying method should be implemented. A hot air circulation system is employed, featuring an equal pressure air supply box and matrix-shaped nozzles to optimize heat exchange and achieve rapid, energy-efficient heating.
The water content in chemical self-hardening sand is very low. Once a water-based coating is applied, the sand absorbs some moisture, allowing the coating to adhere properly. The evaporation of water from the coating meets the requirements of the casting process. The hot air drying process for the sand shovel and sand squeezing differs in depth and intensity. The former focuses on evaporating the paint, while the latter involves drying the sand itself to a deeper level. This distinction allows for improved yield and reduced energy consumption.
The sintering process of the electric furnace lining is determined by the maximum operating temperature and the properties of the lining material. It adjusts according to the moisture content of the lining. The electric furnace tapping trough is made of castables, providing excellent resistance to slag and extending service life, thereby reducing cleaning and maintenance tasks.
When the furnace is shut down, quenching can help reduce cracking in the lining. The use of artificial intelligence regulators improves control accuracy, with parameters that can be adjusted automatically. These regulators offer versatile functions, including programmable temperature curves and adaptive tuning, making them highly efficient for temperature control in the drying process.
The silicon-controlled power regulator is widely used to control the electric heater, improving temperature regulation and reducing maintenance costs. It also minimizes electrical interference and ensures smooth operation. Proper setup and maintenance of the regulator are essential to avoid damage and ensure reliable performance.
In summary, modern foundry technologies such as resin sand casting and advanced drying systems have significantly enhanced the efficiency and quality of casting processes. Continuous improvements in furnace design, control systems, and materials contribute to better performance, lower energy consumption, and longer equipment life. These innovations support the growing demand for high-quality castings in various industries.
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