Centrifugal casting

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Centrifugal casting

Graphite bronze bushing

Centrifugal casting

Centrifugal casting is a highly effective method for producing high-quality bronze components such as rings, bushings, bearing flange bushings, and crowns, particularly for applications in gearboxes and other industrial machinery. This process leverages centrifugal force to distribute molten bronze evenly against the mold walls, resulting in a dense, high-integrity product with superior mechanical properties.

Here’s a breakdown of the key advantages and features of centrifugal casting for bronze components:

  • Key Advantages of Centrifugal Casting for Bronze:

    1. Reduced Porosity:
      • The centrifugal force ensures that any gases or impurities are pushed toward the inner diameter, which can be machined away, leaving a dense, porosity-free outer surface.
    2. Fine Grain Structure:
      • The rapid cooling and solidification under centrifugal force result in smaller grain sizes, which enhance the mechanical properties of the bronze, such as toughness, ductility, and wear resistance.
    3. High Purity:
      • The process minimizes impurities and inclusions, ensuring a clean, homogeneous material structure.
    4. Customizable Dimensions:
      • Centrifugal casting can produce large custom-sized diameters and lengths, tailored to specific client requirements. Dimensional tolerances can be adjusted based on the application needs.
    5. Surface Finish Options:
      • The process can deliver rough machining surface finishes or pre-machined parts, reducing the need for additional machining and saving time and costs.

  • Principal Products of Centrifugal Bronze Casting:

    • Rings: Used in gearboxes, bearings, and other rotating machinery.
    • Bushings: Ideal for high-load, low-friction applications.
    • Bearing Flange Bushings: Designed for heavy-duty industrial applications.
    • Crowns: Used in gearboxes and other mechanical systems requiring high wear resistance.

  • Applications:

    Centrifugal bronze casting is widely used in industries such as:

    • Automotive: Gearbox components, bushings, and bearings.
    • Marine: Propeller bushings and bearing sleeves.
    • Industrial Machinery: High-performance rings and bushings for heavy equipment.
Worker in Factory
Industrial Metal Towers

Why Choose Centrifugal Casting for Bronze Components?

  • Superior mechanical properties compared to static casting or forging.
  • Cost-effective for large, custom-sized parts.
  • High repeatability and consistency in production.
  • Ideal for high-performance applications where durability and reliability are critical.

If you’re looking for custom bronze components with exceptional quality and performance, centrifugal casting is an excellent choice. Let me know if you need further details or assistance with specific requirements!

Continuous casting

Large-size continuous casting bearing designed for applications requiring durability and consistent performance, particularly in large-scale industrial processes.

Manufacture of bronze parts

Production and manufacturing process of bronze components specifically designed for use as bearing bushings.

Centrifugal Casting Process for Bronze Bushings

Centrifugal casting is a manufacturing process that involves pouring molten metal into a rotating mold to produce cylindrical parts. This method is particularly effective for creating bronze self-lubricating bushings, which often incorporate graphite to enhance their lubricating properties. Here’s an overview of the process and the key aspects of producing such parts:

Centrifugal Casting Process for Bronze Bushings

  1. Material Preparation:
    • Bronze Alloy: Typically, a bronze alloy (such as C93200 or C95400) is chosen for its excellent wear resistance and low friction properties.
    • Graphite: Graphite is added to the bronze alloy to provide self-lubricating characteristics. This can be done by mixing graphite powder with the molten bronze or by embedding graphite plugs into the casting.
  2. Mold Setup:
    • A cylindrical mold is prepared, often made of steel, and preheated to a specific temperature to ensure proper flow and solidification of the metal.
    • The mold is mounted on a centrifugal casting machine, which will rotate it at high speeds.
  3. Pouring and Casting:
    • The molten bronze (with or without graphite) is poured into the rotating mold.
    • Centrifugal force distributes the molten metal evenly along the mold’s inner surface, creating a dense and uniform structure.
    • The rotation continues until the metal solidifies.
  4. Cooling and Ejection:
    • After solidification, the mold is stopped and allowed to cool.
    • The casting is then ejected from the mold.
  5. Machining (CNC):
    • The rough casting is machined to achieve the final dimensions and surface finish. CNC machining ensures high precision and consistency.
    • Key features such as inner and outer diameters, grooves, and holes are machined as per the design specifications.

Key Features of Bronze Self-Lubricating Bushings

  • Self-Lubrication: The embedded graphite provides continuous lubrication, reducing the need for external lubricants and maintenance.
  • Wear Resistance: Bronze alloys are known for their durability and resistance to wear, making them ideal for high-load and high-speed applications.
  • Corrosion Resistance: Bronze offers good resistance to corrosion, especially in harsh environments.
  • Low Friction: The combination of bronze and graphite results in a low coefficient of friction, enhancing the efficiency of the bushing.

Applications

Bronze self-lubricating bushings are used in various industries, including:

  • Automotive: For suspension systems, steering components, and engine parts.
  • Industrial Machinery: In conveyor systems, pumps, and heavy equipment.
  • Marine: In propeller shafts and other components exposed to seawater.

Advantages of Centrifugal Casting

  • High Density and Strength: The centrifugal force ensures a dense and strong casting with minimal porosity.
  • Material Efficiency: The process minimizes waste as excess material can be recycled.
  • Uniformity: Produces parts with consistent wall thickness and mechanical properties.

CNC Machining Considerations

  • Precision: CNC machining allows for tight tolerances and complex geometries.
  • Surface Finish: Achieves smooth surface finishes, which are crucial for the performance of bushings.
  • Customization: Enables the production of custom-designed bushings tailored to specific applications.

By combining centrifugal casting with CNC machining, manufacturers can produce high-quality bronze self-lubricating bushings that meet the demanding requirements of various industrial applications.

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