V-process casting
V-process casting, short for “vacuum process casting,” is a distinctive sandless casting technique. It uses two V-shaped molds with a thin layer of bondable sand powder compacted between them. This forms a mold cavity that closely resembles the final casting shape. The process relies on a vacuum system to compact the sand using pressure differences. Here’s how it works:
- Mold Formation:
A plastic film is heated (80–120°C) and tightly sealed over a pattern using a vacuum pump. Dry quartz sand (100–200 mesh) is then filled into the mold box, compacted using micro-vibration, and covered with another plastic film. The vacuum creates a pressure difference (300–400 mmHg), hardening the mold. - V process casting Process:
- Once the mold cavity is ready, cores are placed, and the mold is sealed.
- Metal is poured into the vacuum-sealed cavity, where it solidifies.
- After cooling, the vacuum is released, allowing the mold to collapse. This results in a clean casting, and the sand can be reused.
- Advantages:
Unlike traditional sand casting, it doesn’t use adhesives, which makes it environmentally friendly and cost-effective. The absence of binders also eliminates sand-related defects on the casting surface. - Vacuum System:
The vacuum system, comprising a pump, pressure-stabilizing tank, and dust removal setup, is critical. It maintains a vacuum level of approximately -66500 Pa (-500 mmHg), ensuring consistent mold compaction and quality. - Step-by-Step Process Overview:
- A plastic film is heated and vacuum-sealed over the pattern.
- Dry sand is added, compacted, and covered with another plastic layer.
- The vacuum forms a high-hardness mold (wet mold hardness ~95).
- After demolding, the mold remains vacuumed until casting solidifies.
- The vacuum is released, and the sand collapses, leaving a clean casting.
V-process casting, similar to lost foam casting, excels in precision and reusability of materials while simplifying mold preparation and cleanup.
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