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The foundry industry has gradually become an important concern for carbon emissions. The composite patternless casting, which combines sand mould 3D printing and sand mould milling technologies, is an effective way to explore the potential of energy saving and emission reduction in the foundry industry. However, the technical advantages of composite patternless casting in terms of energy saving and emission reduction have not been fully studied. To address this issue, this paper combines the composite patternless casting with the modular division method, and proposes a influence modelling and analysis method for carbon emissions and carbon efficiency ratio based on the process characteristics stage. The model and method are applied to the patternless casting process of a cylinder block. And the modular division schemes of the mould were proposed. The results show that through different modular division schemes, carbon emissions can be effectively reduced by 8.39%, the carbon efficiency ratio can be increased by up to 30%. This method is helpful to describe the carbon emission influence of the patternless casting forming process, and analyse the energy saving and emission reduction potential and carbon efficiency of the process.

An influence modelling and analysis method of reducing carbon emissions for mould forming processes in patternless sand casting