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The accuracy of the castings and the economic performance of the production process mainly depend on this process. In many modern counterweight iron workshops, the molding and core-making have been mechanized or automated. The commonly used sand mold and core-making equipment includes high-pressure, medium-pressure and low-pressure molding machines, sand polishing machines, boxless injection molding machines, injection core-making machines, cold and hot core box machines, etc.
The process of manufacturing the counterweight iron for a forklift can be divided into three basic parts: the preparation of the counterweight iron metal, the preparation of the casting mold, and the processing of the castings. The counterweight iron metal refers to the metal material used for pouring the castings in the production of the counterweight iron. It is an alloy composed mainly of a metal element and other metal or non-metal elements. It is commonly referred to as counterweight iron alloy, and the main types include cast iron, cast steel, and counterweight iron non-ferrous alloys. According to the different material of the casting mold, the counterweight iron for a forklift can be divided into two major categories: one type uses natural mineral sands and stones as the main casting material, such as lost-wax counterweight iron, shell mold counterweight iron, negative pressure counterweight iron, clay mold counterweight iron, solid mold counterweight iron, ceramic mold counterweight iron, etc.; the other type uses metal as the main casting material, such as metal mold counterweight iron, centrifugal counterweight iron, continuous counterweight iron, forklift accessory iron, low-pressure counterweight iron, etc.
The design of the counterweight block should not only meet the requirements of the machine equipment itself and the requirements of mechanical processing, but also comply with the requirements of casting technology. The structural design of the counterweight block should pay attention to the following points:
1. It should be convenient for manufacturing the model, core box and mold:
1) The shape of the counterweight block should be as simple as possible to facilitate mold removal. The casting parting surface should be a plane as much as possible, and the number should be kept small.
2) The inner cavity of the counterweight block should be designed in such a way that no or as few cores as possible are used during casting. When cores are employed, they should facilitate support, fixation, and sand discharge and removal, and should also have sufficient process holes.
3) For the inner and outer surfaces of the counterweight blocks as well as the reinforcing ribs and other structures, structural slopes should be provided in the direction of mold release.
4) The protruding part on the counterweight block should not be too different from the main body of the counterweight iron. It is preferable to be at the same height and have a relatively close distance between several protrusions on the same surface, so that they can be connected as a continuous raised part.
