(1) The document discusses the development and progress of V-process casting in China. It began being studied in 1974 and has grown significantly, with over 500 firms now using the technique. (2) The key aspects of V-process casting are that it uses vacuum instead of binders in the sand mold. This allows for high dimensional accuracy and surface quality in castings. (3) The document outlines the history and increasing applications of V-process casting in China. It is now used for castings in various industries such as machinery, rail, automotive, and more. The technology and equipment for V-process casting in China has also advanced greatly.

1. ChineseTechnology Association of Lost Foam Casting and
V-process Casting
Development and Progress of V-process Casting in China
Huazhong University of Science And Technology State Key
Laboratory of Meterials Processing and Die&Mould Technology
V-process team：Zhang Jianman, Tu Yiming,Liang Qingmin,Chen Min,
Xiong Lingda,Zhu Peng,Ke Hao,Qiao Yun,Yang Junlu,Zhang Yu,Liu
Liangcai.....
Web:www.xsm-v.com.cn Email：zhangjianman66@163.com
Phone:+8613545239290 +86 15907126574
Address:No.1037，Luoyu Road,Hongshan District,Wuhan,Hubei,China

2. theory of V-process technique
Magdeburg hemispheres
experiment
pressure difference is key
factor for the technique;
vaccum pump offers
possibility for P-difference

3. What is V-process?

4. fundamental equipments for V-
process casting
vacuum serves as binder material
V-process casting: the third generation molding method

5. Special Properties and Requsts of V-process
1 no binders but dry sand
2 special film for foaming with high extensibility
3 vacuum serves as binder and needed in the
whole process
4 special coating for use and play important role
5 special flasks with double wall and filter pipes
6 vibration with high frequency and low amplitude

6. developing history
• 1974.huazhong industrial college (now HUST)begun studying for the
technique;
• 1980~1990.several old line was introduced in china from japan;
• 1990~2000.chinese domestic firms start studying and manufacturing V-
process equipment;meanwhile EVAfilm and coating for V-process had a
big progress in property and cost;
• 2000~2010.more firms specially producing V-process equipments ,EVA
film and special coating;V-process form great influencement in chinese
foundry field;
• 2010~now.more and more firms find adventage of V-process and pay
more attention to it;it is playing important role on chinese foundry'changing
and adjustment;
HUST form a team specially for V-process casting studying and
application,including equipment,pattern,EVA film,coating,and foundry
technique;

7. over 500
firms by
V-process
77%
cast iron
21%
cast steel
nonferrous alloy
large to small
cast iron to cast steel to nonferrous alloy even nonmetal castings
low level to high grade
calculated on 2012,12

8. about 200
firms by
V-process
75%
cast iron
21%
cast steel
nonferrous alloy
market influencement
international competition
wear resistant casting and nonferrous alloy casting are increasing
calculated on 2014,12

9. SN firm name casting production
1 Hefei Casting &Forging Factory Counterweight 130,000 tons/year
2 Dingzhou Dongfang Foundry Co. Ltd. Counterweight 120,000 tons/year
3
Fujian Changfeng Axle Manufacturing
Co. Ltd
Cast steel axle housing 30,000 tons/year
4 Tianrui Group Foundry Co.Ltd Bolster、Side frame 200,000 tons/year
5 SANY Heavy Industry Track Shoes 30,000 tons/year
6 Haimen Qilong Fonudries
High manganese steel
jaw、Crushing wall
20,000 tons/year
7
The Warm-master(Shandong) Cast
Iron Boiler Co., Ltd.
Piece cast iron boilers 5000tons/year
8
China Railway Shanhaiguan Bridge
Group Co.Ltd
High manganese steel
turnout
7000tons/year
9 IKK(Dalian)Co.,Ltd.
Heat-resistant steel
frame material、Trays
2000tons/year
10 Roca (Suzhou) Co.,Ltd. Cast iron bathtub 6000tons/year
11
Fujian Dexin Machinery
Manufacturing Co., Ltd. Copper Valve 3000tons/year
12 Wuxi HuaXinXing mould co., Ltd. Aluminum mold 2000tons/year
…… ……………… .……….. ……….

10. Progress of Equipment
——self-making replace importing
semi-automatic and high-automatic V-process molding line
over 10 firms specially producing V-process production
line in china now
5~7molds/h for counterweight 10molds/h for axle box

11. Progress of Key Material
EVA film and coating decides the running cost even casting
quality and application fields
Improvement of EVA film
especially elongation and cost
contributes to V-process' progress
coating quality influnces casting
quality and later

12. progress of technical study
1·1974 huazhong industrial college(now HUST) professor
caowenlong start to study V-process casting and form the initial
technique system and a reference book《vacuum molding》;
2·2007HUST professor yeshengping furtherly expanded the
study range and promoted the progress of
EVAfilm,coating,equipments and application;then edit 《V-
process casting photo album》
3·2011 HUST researcher zhangjianman form a studying team
specially for V-process and moredetailedly,systematicly;
especialy concentrating on casting quality ,production
economic ,high-level and automatic molding line and so on;

13. Typical Cases——Engineering Machinery Castings
gearbox
counterweight
axle housing

14. Railway Castings
sideframe frog
draw gear bolster

15. autobobile parts
axle housing axle cover
drum brake brake disc

16. petroleum machinery castings
box
pumping unitsupport
crank/rocker

17. Mining&crushing Machinery Wear-resistant Casting
hammer rolling mortar wall
jaw plate
jaw plate track shoe

18. art and life
piano framework
bathtub
dustbin
Exterior wall

19. public construction
tunnel supporting plate
manhole cover transporting tube
electrical valves

20. Metallurgy Machinery
coke oven -furnace door electrode
charging tray of heat treatmentmold for copper metallurgy

21. Reasons for Selection and Application
• high accuracy—— net shaping
• zero draft
• surround side machining allowance cancelled
• up plate surface machining allowance be 1/3 before
• V-process casting VS sand casting

22. Reasons for Selection and Application
• high accuracy—— net shaping
high dementional accuracy and low machining
allowance save cost to a great dgree

23. Reasons for Selection and Application
• high quality—— good surface quality
low coarse improve tired life and assembling accuracy
if controlled well,V-process casting surface quality
can be good as investment casting

24. Reasons for Selection and Application
• high quality—— little/noun flaw and low foundry stress
for thin wall caststeel casting with complicated structure
V-process casting offers better solution than resin sand and
sodium silica sand comparing all factors;

25. Reasons for Selection and Application
• low cost—— request of market competition
dry sand no binders ,sand circulation easily
and little waste;
low labour strength lead low labour cost;
low wear make pattern cost low;
low environmental cost
........

26. Reasons for Selection and Application
• environmental —— request of modern industrial
no harmful gas and wastes;
dust from dry sand and noise from vaccum pump
are main pollution factors,
but easily controlled;
investment for environmental equipments will be low
in future foundry shop

27. Reasons for Selection and Application
——low labour strength：molding relaxedly and shaking out
easily;

28. summary
-application field of V-process
(1)medium-big castings with some quatity
previously casted by chemical binder sand
especially ester-hardening water glass sand
and resin sand,co2 water glass sand
adventage:production,cost,environment,
labour strength,quality
it does not means all of the adventages will be reflected on
the same casting,but must have some typical adventages;

29. summary
-application field of V-process
(2)castings with some quatity but still little or
dimentional big for high pressure molding
line but hand-molding can not offer a good
quality;
adventage:labour strength,quality
production,environment,
it does not means all of the adventages will be reflected on
the same casting,but must have some typical adventages;

30. summary
-application field of V-process
(3)castings with little even single quatity but
have high requests on surface coarse or
dementional accuracy or machining;
adventage:surface quality,dimentional
accuracy,machining,environment,
it does not means all of the adventages will be reflected on
the same casting,but must have some typical adventages;

31. Previous Faults and Setbacks
1lack of right guidence make some improper casting used
on V-process
2 variety of casting defects make YIELD low
3 unreliable equipments and materials make production low
and quality unstable;
4 neglect of dust-cleaning measures make V-process shop
environment bad;
5 speciality like cooling rate of V-process on inner quality
has not been payed enough attention

32. Expectation and Tendency
1 more study and improvement on casting
quality problem
2 develop better film and coating even
special risers for V-process
3 high molding-rate line for large production
casting
4 high automatic-level shop for little/none
workers production
5 environmentol shop with low wastes and
polution

33. Personal Profile of Team Director
Zhang jianman
Foundry Engineer
Secretary-General of Chinese technological
association of Lost Foam Casting and V-process
casting
Researcher of Huazhong University of Science
And Technology
State Key Laboratory of Materials Processing and
Die&Mould Technology
Cell phone:+86 13545239290; +86 15907126574
Fax:+86 027-87558143
Address:No.1037,luoyu road,hongshanDistrict,
wuhan,hubei,china;430074
Email:zhangjianman66@163.com
QQ:1937943818
Web:www.xsm-v.com.cn