🔧 Optimization of Flywheel Production in Vertical Molding Lines (Green Sand)
Project Overview:
To enhance product quality and production efficiency, a comprehensive engineering project was carried out to optimize the manufacturing process of cast iron flywheels in vertical green sand molding lines. The flywheel, a critical component in power transmission systems, demands exceptional structural integrity, dimensional accuracy, and metallurgical consistency. However, due to its high modulus and complex geometry, it posed significant casting challenges, particularly in terms of feeding and defect control.
Implemented Solutions:
The project began with a detailed review and redesign of the gating system, targeting critical hot spots and feeding zones. Through metallurgical and thermal analysis, improvements were made to the melting process to ensure stable chemistry, reduced turbulence during pouring, and minimized inclusions. Innovative directional solidification techniques were applied to eliminate the need for conventional feeders, significantly improving metal yield.
Key Achievements:
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✅ 20% increase in part yield and production efficiency
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✅ Complete elimination of feeders, reducing scrap due to shrinkage and cold shuts
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✅ Improved microstructural uniformity and graphite distribution
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✅ Significant cost savings in raw materials and post-casting processes
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✅ Enhanced process stability and better quality control in mass production
This project stands as a successful case of applying advanced process engineering and casting expertise to reduce waste, optimize performance, and deliver higher-value industrial components.
