When casting cylinder blocks, a mold is a key part of the process. This mold is used to shape the parts, which are then cast into the desired shapes. The process of making cylinder block molds requires the use of a number of reagents to achieve the desired quality and consistency of the finished product. These reagents are used to ensure that the components produced are safe to handle.
The sand mixture that is used to make the mold has to be poured around the pattern to ensure that it does not crack while casting. The risers, which are usually 8 large holes, are also an important part of the process. The risers help the metal stay molten even during the casting process, as they supply the molten metal as it shrinks. The aluminum block casting is then machined to achieve the desired dimensions and smooth surfaces.
The molding sand in the plant has a content of between eight and ten percent effective bentonite and 10-12% total mud. The molding sand is mixed in a sand mixer and the temperature is 20°C. The maximum temperature in the summer is thirty degrees. The used sand prior to entering the sand mixer is usually about 40-45 degrees. It contains around 1.5-2 % moisture.
The casting process can be optimized through simulation tools. The use of sand cores can result in a high-quality casting with minimal stress and dimensional accuracy. Low-pressure sand casting is recommended for prototypes and small series of castings. Low-pressure sand casting allows the melt to enter the mold under a low pressure of 0.1 to 0.5 bars. The results of this process are high-quality cylinder blocks with minimal casting defects.
Aluminum alloys are another popular material for engine blocks. These materials offer similar properties to cast iron, including low weight and thin oil ducts. The weight of an aluminum alloy cast engine block is approximately one-third the weight of the same weight as that of cast iron. In addition, it's lightweight and easy to machine. It's also cheaper and more abundant. When choosing a mold, it's important to consider the material.
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