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Automobile Casting Process Knowledge And Technology Development Trend Approximately 15% to 20% of the auto parts are castings produced by different casting methods. These castings are mainly key components of the power system and important structural components. At present, Europe and the United States automobile industry developed countries, automobile casting production technology is advanced, product quality is good, high production efficiency, environmental pollution. Casting raw and auxiliary materials have been formed series and standardization, the entire production process has been achieved mechanization, automation and intelligence. These countries generally use digital technology to improve the level of casting process design, casting scrap rate of about 2% to 5%, and has established a multinational service system and network technology support. In contrast, although China's automobile castings larger output, but most of them are low value-added and low technical content, the structure is relatively simple black castings, and the gap between foreign level. This article mainly discusses the development direction of automobile casting and automobile technology from the development demand of automobile energy saving and environmental protection. The direction of development of automotive castings 1.1 integrated design of automotive castings With the automotive energy saving and reduce the cost of production requirements continue to increase, make full use of the advantages of casting, the original stamping, welding, forging and casting forming several parts, through a reasonable design and structural optimization, to achieve integrated parts casting Forming, can effectively reduce the weight of parts and reduce the unnecessary processing of the process, in order to achieve the weight of parts and high performance. The development trend of automobile casting integration is more obvious in the development of nonferrous alloy castings. In order to make full use of the casting process to achieve the characteristics of the production of complex structural castings, there have been integrated design of the door panels, seat skeleton, dashboard skeleton, front frame and firewall integrated design of high-pressure castings, the size is significantly larger than the current production Casting, the need for 4 000 ~ 5 000 t or even larger tonnage die-casting machine for production. 1.2 The weight of automotive castings To ensure the strength and safety of the car under the premise of the car as much as possible to reduce the quality of the preparation, to achieve lightweight, thereby enhancing the vehicle's power, reduce fuel consumption and reduce exhaust pollution. The quality of the vehicle is reduced by 100 kg and the fuel consumption per 100 km can be reduced by 0.3 to 0.6 L. If the vehicle weight is reduced by 10%, the fuel efficiency can be increased by 6% to 8%. With the needs of environmental protection and energy conservation, the weight of the car has become the world's automobile development trend, the weight of automotive castings has become one of the important direction of development of automotive castings. The development direction of automobile casting technology Production technology of thin - walled complex structure castings With the development of the automobile industry and the demand for energy saving and emission reduction, the weight of automobile parts is becoming more and more lightweight. Through thin-walled design, it is an important development direction of engine block. FAW Casting Co., Ltd. for the FAW Volkswagen production cast iron cylinder, for example, the early production of 06A cylinder wall thickness 4.5mm ± 1.5 mm, EA111 cylinder wall thickness 4 mm ± 1 mm, the current mass production EA888Evo2 cylinder wall thickness 3.5 mm ± 0.8 mm, the next generation EA888Gen.3 cylinder product structure is more complex, the wall thickness of only 3mm ± 0.5 mm, is the thinnest gray cast iron cylinder. In the mass production, there are some problems such as broken core, drift core and wall thickness fluctuating. However, by controlling the quality of sand core and sand, But can not meet the EA888Gen.3 cylinder production requirements, must be used as a whole group of core pouring process. 2.2 Aluminum-magnesium alloy large-scale structural parts manufacturing technology With the increasing demand for energy saving, environmental protection and cost reduction, aluminum-magnesium alloy large-scale structural casting has become an important development trend, and its manufacturing technology has become the current development hotspot. At present, the main production technology of aluminum-magnesium alloy large-scale structural parts is high-pressure casting, extrusion casting and low-pressure casting. As the high-pressure casting production efficiency, product quality has become the main production process, its manufacturing technology development focused on the high-pressure casting process is easy to curl, casting easy to form pores, can not heat treatment problems. 2.3 Casting Precision Casting Technology Commonly referred to as the precise casting of automotive casting mainly refers to the elimination of mold and investment casting technology. With the development of automobile casting forming technology, casting precision forming is a kind of casting forming method. Castings produced by this type of forming method can be used directly without cutting or cutting. With the improvement of casting size precision, casting precision forming technology has been developed rapidly in recent years, and a series of new casting methods have been developed such as precision sand casting, Lost Foam Casting, Controlled Pressure Casting and Pressure Casting. The Cosworth casting method was developed by the UK using a combination of zirconium sand core and controlled by an electromagnetic pump. It has been successfully used for mass production of aluminum alloy cylinders and has appeared in many process variants such as low pressure casting instead of electromagnetic Pump casting and other processes. The use of this type of casting method can produce wall thickness of 3.5 ~ 4.0 mm aluminum alloy cylinder, is the current precision sand casting on behalf of the process. In the high-pressure casting process developed on the basis of vacuum casting, oxygenated die-casting, semi-solid metal rheological or thixotropic die-casting process, designed to eliminate casting defects, improve internal quality and expand the scope of die casting applications. In the process of extrusion casting, the melt is filled and solidified under pressure, and has the advantages of smooth, no metal splashing, less loss of metal liquid oxidation, energy saving, safe operation and defects of casting hole. High-performance aluminum alloy casting the development and application of a wide range of applications. The continuous growth of automobile production requires the casting production to high quality, excellent performance, near net shape, multi-species, low consumption, low cost direction. As a vehicle about 15% to 20% of the parts are castings. This requires the casting industry to continue to use a variety of new technologies, new materials to enhance the overall level of casting. Casting precision casting technology can meet the above requirements of automotive castings, and its applications will also cover the different casting processes of automotive castings. In order to meet the increasingly demanding environmental regulations, cars are moving towards light weight. Reduced vehicle weight by 10%, fuel consumption can be reduced by 5.5%, fuel economy can be increased by 3% to 5%, while reducing emissions by about 10%. Application of aluminum and magnesium and other nonferrous alloy castings, the development of large complex structure of integrated castings and extensive application of precision casting molding technology is to achieve the main way to reduce the weight of automotive castings. And therefore requires extensive use of digital technology on the basis of high-performance casting materials, automation equipment, such as a wide range of means to achieve the development and production of automotive castings to meet the needs of modern automotive industry.
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Otprilike 15% do 20% auto dijelovi su proizvedeni metodama različitim lijevanje odljevaka. Ove odljevci su uglavnom ključne komponente elektroenergetskog sustava i važne strukturne komponente. U ovom trenutku, Europi i sad-u automobilske industrije razvijenih zemalja, napredne tehnologije proizvodnje automobila lijevanje, kvaliteta proizvoda je dobar, visoke proizvodne učinkovitosti, zagađenje okoliša. Lijevanje sirovog i pomoćni materijali su formirane serije i standardizaciju, proizvodnja je bila postići mehanizacija, automatizacija i inteligencije. Tim zemljama općenito korištenje digitalnih tehnologija poboljšati razinu lijevanje proces dizajna, lijevanje škarta stopa od oko 2% do 5%, i uspostavio multinacionalne usluga sustava i mreža tehnologija podrška. S druge strane, iako Kina je auto odljevaka veće proizvodnje, ali većina njih su niske dodane vrijednosti i niske tehnički sadržaj, struktura je relativno jednostavna Crna odljevaka i jaz između stranih razini. Ovaj članak uglavnom govori o razvoju smjeru automobila lijevanje i automobilske tehnologije iz razvoj potražnje auto energije i zaštite okoliša. Smjer razvoja automobilske odljevaka 1.1 integrirani dizajn automobili odljevaka S automobilskom ušteda i smanjenje troškova proizvodnje uvjeti i dalje povećava, iskoristite prednosti lijevanja, originalni tisak, zavarivanje, kovanje i lijevanje formiranje nekoliko dijelova, kroz razuman dizajn i strukturna optimizacija, kako bi se postigla integrirani dijelovi lijevanje Forming, možete učinkovito smanjenje težine dijelova i smanjiti nepotrebne obrade procesa, kako bi se postigla težina dijelova i visoke performanse. Trend razvoja automobilske lijevanje integracije je očitije u razvoju odljevaka obojenih legura. Kako bi se u potpunosti iskoristio procesa lijevanja postići karakteristike proizvodnju složenih strukturnih odljevaka, bilo je integrirani dizajn vrata, sjedala kostur, nadzorna ploča kostur, prednji okvir i vatrozid integrirani dizajn Visokotlačni odljevaka, veličina je znatno veća od trenutne proizvodnje Casting, potreba za 4 000 ~ 5 000 t ili čak i veće tonaže umrijeti-lijevanje stroj za proizvodnju. 1.2 težina automobilski odljevaka Snagu i sigurnost automobila pod prostor auto što više smanjiti kvalitetu pripreme, kako bi se postigla lagan, potičući vozila moći, smanjiti potrošnju goriva i smanjenje ispušnih zagađenje. Kvaliteta vozila je smanjena za 100 kg i potrošnja goriva na 100 km može se smanjiti 0,3 do 0,6 L. Ako težina vozila je smanjena za 10%, potrošnja goriva može se povećati za 6% do 8%. Za potrebe zaštite okoliša i očuvanje energije, težina auta je postala svjetski automobilski razvoj trenda, težina automobilski odljevaka je postao jedan od važan smjer razvoja automobilske odljevaka. 2. razvoj smjera automobila lijevanje tehnologija Proizvodna tehnologija tankih - stijenki kompleksne strukture odljevaka Uz razvoj automobilske industrije i potražnje za uštedu energije i emisije smanjenje težine dijelova za automobilsku industriju postaje više lagan. Kroz dizajn kanalice, to je važan razvoj smjera blok motora. Marko Casting Co, Ltd za FUADA Volkswagen proizvodnju lijevanog željeza cilindra, na primjer, početkom proizvodnje 06A cilindar zid debljine 4.5mm ± 1.5 mm, EA111 cilindar zid debljine 4 mm ± 1 mm, trenutne masovne proizvodnje EA888Evo2 cilindar zid debljine 3,5 mm ± 0,8 mm, nove generacije EA888Gen.3 cilindar proizvod struktura je složeniji, debljina od samo 3mm ± 0,5 mm, je najtanji sivog lijevanog željeza cilindra. U masovnoj proizvodnji, postoje neki problemi poput slomljena jezgre, zanošenje jezgra zida debljina varira. Međutim, po kontroli kvalitete pijesak core i pijeska, ali ne mogu zadovoljiti potrebe proizvodnje EA888Gen.3 cilindra, moraju se koristiti kao grupa jezgra lije proces. 2.2 aluminij-magnezij legure velikih strukturnih dijelova proizvodnih tehnologija Uz sve veću potražnju za štednju energije, zaštite okoliša i smanjenje troškova, aluminij-magnezij legure velike strukturne lijevanje postala važan razvoj trend i proizvodnih tehnologija je postala trenutni razvoj hotspot. U ovom trenutku, glavna proizvodna tehnologija aluminij-magnezij legure velikih strukturnih dijelova je visokotlačni lijevanje, ekstruzija lijevanje i niskog tlačnog lijevanja. Kao visokotlačnog lijevanja učinkovitost proizvodnje, kvalitete proizvoda je postao glavni proizvodni proces, svoje proizvodne tehnologije razvoja usmjerena na proces visokotlačnog lijevanja je lako nakovrčati, lijevanje lako da oblik pora, može ne toplinske obrade problema. 2.3 lijevanje precizno lijevanje tehnologija Obično se nazivaju precizno lijevanje automobilski lijevanje uglavnom se odnosi na uklanjanje plijesni i tehnologiji lijevanja ulaganja. S razvojem automobila lijevanje formiranje tehnologija, lijevanje preciznost formiranje je Casting formiranje metoda. Odljevci u produkciji ove vrste formiraju metoda može se koristiti izravno, bez rezanja ili rezanja. Napredak lijevanja veličina preciznosti, lijevanje preciznost formiranje tehnologija ubrzano razvijao u posljednjih nekoliko godina, i niz novih lijevanje metode razvijene su kao što su preciznost pijeska lijevanje, izgubio lijevanje pjene, kontrolira tlak lijevanje i pritisak. Cosworth lijevanje metoda je razvijena od strane Velike Britanije u kombinaciji Cirkonij pijesak jezgre i kontrolom elektromagnetskih pumpa. To se uspješno koristi za masovnu proizvodnju aluminijske legure cilindara i pojavio se u varijante procesa kao što su niski tlak lijevanje umjesto elektromagnetske pumpa lijevanja i ostale postupke. Korištenje ove vrste metodom lijevanja može proizvesti debljina 3,5 ~ 4,0 mm aluminijske legure cilindar, je trenutni preciznost pijeska lijevanje u ime procesa. U procesu visokotlačnog lijevanja razvio vakuum lijevanje, kisikom umrijeti-lijevanje, polu-čvrsta metalna reološka ili tiksotropna umrijeti-lijevanje proces, osmišljen kako bi se uklonili nedostaci lijevanja, poboljšati unutarnju kvalitetu i proširiti opseg umrijeti lijevanje aplikacija. U procesu ekstruzije lijevanje, rastopiti je ispunjen i učvrstili pod pritiskom i ima prednosti glatko, bez metala prskanje, manji gubitak metala tekući oksidacije, ušteda energije, siguran rad i nedostaci lijevanja rupu. Povisok-izvođenje aluminijskih legura lijevanje razvoj i primjena širok spektar aplikacija. Kontinuirani rast proizvodnja automobila zahtijeva lijevanje proizvodnje visoke kvalitete, odlične performanse, u blizini neto oblika, vrsta, niske potrošnje, niske cijene smjeru. Kao vozilo za oko 15% do 20% dijelova se odljevaka. To zahtijeva lijevanje industrije da i dalje koristiti različite nove tehnologije, Novi materijali kako bi se poboljšala Ukupna razina lijevanje. Lijevanje precizno lijevanje tehnologija mogu zadovoljiti gore navedene zahtjeve automobilski odljevaka i njene primjene pokriva i različitim lijevanje procesa automobilski odljevaka. Kako bi se zadovoljile sve zahtjevnije ekoloških propisa, automobila se kreću prema lagani. Smanjena vozila težine za 10%, potrošnja goriva može se smanjiti za 5,5%, potrošnja goriva može se povećati za 3% do 5%, dok je smanjenje emisije za 10%. Primjena aluminija i magnezija i drugih obojenih aluminijski odljevci, razvoj velike kompleksne strukture integrirani odljevaka i niz precizno lijevanje oblikovanje tehnologija je postići glavni način za smanjenje težine Automobilski odljevaka. I stoga se koristi digitalne tehnologije na temelju visokih performansi lijevanje materijala, opreme za automatizaciju, kao što je širok raspon je postići razvoj i proizvodnja automobilskih Odljevci za potrebe suvremenog Automobilska industrija.