镁合金进气歧管金属型倾转铸造工艺

利用Anycasting铸造模拟软件,对采用金属型倾转铸造镁合金进气歧管的工艺进行了研究.通过正交试验和数值模拟,找到倾转铸造镁合金进气歧管的最优工艺参数.正交试验表明,金属型预热温度对倾转铸造镁合金进气歧管的模拟结果影响最大,然后依次为倾转速度、浇注温度、浇口杯预热温度.在浇注温度为750 ℃,上型预热为450 ℃,下型预热为550 ℃,浇口杯预热为550 ℃,倾转速度为2.71 r/min的条件时,模拟结果最好.     

工业发动机铝合金进气歧管的壳型铸造工艺

某国外工业发动机铝合金进气歧管铸件壁薄、热节多,内部的气道和冷却水道交错,结构复杂。对其结构仔细分析,决定采用壳型工艺进行试制。本文从壳型工艺的浇注系统设计,模具设计,制芯和制壳工艺方面详细介绍铝合金进气歧管铸件的生产方法。利用壳型铸造工艺方法生产2年多来,质量稳定。     

铝合金进气歧管的铸造工艺

介绍了铝合金进气歧管倾转铸造工艺、浇注系统设计与模具设计,针对生产中容易产生的缩孔、缩松等铸造缺陷制定出合理的工艺方案.选择浇注时间为9.5 s、内浇道截面积为1 500 mm2、模具温度为200-250℃、浇注温度为(710±10)℃.采用芯头部位抽气、厚大部位快冷及补缩等措施来解决铸造缺陷,提高了铸件品质.     

进气岐管铸造工艺模拟及工艺研究

铝合金进气歧管在国产化过程中，由于缩孔和气（针）孔问题，其合格率很低。根据工艺要求，建立了进气歧管的实体模型，对其铸造过程的流动和凝固现象进行了数学物理模拟，并利用商业化的MAGMAsoft软件对其浇注和凝固过程进行了流场和温度场的分析，预测了其铸造过程可能发生缩孔和卷气等缺陷的位置。根据模拟分析的结果，从工艺上采取了相应的措施，通过引入排气管和放大冒口，将产品合格率由原来的20％左右提高到了93％左右。     

消失模铸造法生产CA488发动机进气歧管

介绍了消失模法生产进气歧管的工艺过程、过程控制参数及主要设备。生产表明,采用ＥＰＣ法生产进气歧管,既提高了生产率又改善了铸件品质。     

汽车发动机塑料进气歧管成型工艺的研发与应用

以具有动力性能好、节能和环保等特点的汽车发动机塑料进气歧管为例,研究了汽车发动机塑料进气歧管成套技术中的模具设计、注射工艺、焊接工艺等关键技术,结合CAE技术实现了工艺与模具结构的优化。通过该成套技术的实际应用,满足了汽车工业的要求,为该工艺的进一步推广应用提供了理论指导和技术支撑。     

汽车进气歧管成型工艺分析及注射模设计

通过对汽车发动机核心塑件(一体成型塑料进气歧管)的结构工艺分析,确定模具整体成型和出模结构,通过模流分析,确定胶口位置及布局形式,介绍了一体成型塑料进气歧管注射模设计的关键点和模具制造过程中的注意要点。     

塑料进气歧管的研究进展

塑料进气歧管以其质轻价廉、性能优异等优点正在逐步替代金属进气歧管，其性能在今后的发展中必须不断提高以适应越来越苛刻的发动机工作环境。综述了塑料进气歧管的加工方法、材料选择和改性方面的研究，同时介绍了塑料进气歧管国内外发展现状、应用趋势及新动向，指出必须开发新型材料和加工方法，以满足进气歧管综合性能不断提高的要求。     

J339B型多功能可倾式金属型重力铸造机的研发与应用

J339B型多功能可倾式金属型重力铸造机是一种沿机器轴线倾转的铸造机,它是为了满足倾转浇注工艺而设计研发的。该机广泛用于生产汽车用铝合金进气歧管和摩托车用铝合金减震器套筒以及高压开关用铝合金铸件,由于该机具有高度的通用性和先进性,从而大大提高了模具设计的自由度,有效地降低了铸件废品,使铸件良品率达到95%以上。     

奥氏体耐热铸钢排气歧管铸造工艺研究

针对奥氏体耐热钢的性能特点和工艺特性,采用中频感应电炉炉底吹氩精炼、炉内及包内复合强力脱氧工艺、壳型成型工艺、负压浇注工艺成功研发了奥氏体耐热钢排气歧管。结果表明排气歧管具有良好的力学性能、热疲劳性能和抗氧化性能。     

福特电喷进气歧管金属型重力铸造工艺

分析了福特电喷进气歧管热节分散的结构特点。推荐了该类产品金属型重力铸造工艺常用的化学成分，开放式浇道在实践中的合理应用。指出了金属型重力铸造工艺设计的关键在于对铸件热节分布规律以及铸型温度场分布规律的分析等实践经验。针对生产中发生的渣孔、气孔缺陷制定了控制熔炼温度，注意变质处理时间，合理的涂料操作要求等工艺控制措施。     

基于快速原型技术的进气歧管模具制造

介绍了以快速原型技术和精密铸造技术进行进气歧管铸造模具制造的情况。结果表明，该工艺可更充分地发挥快速原型技术和精密铸造的优势，取得了缩短工期和降低成本的效果。     

铸造工艺CAD/CAE在进气管设计中的应用

将铸造工艺CAD／CAE系统应用到汽车进气管零件的设计中，能够较完整地完成三维实体造型到最后生成模具的全过程。在UG造型软件基础上开发了铸造工艺CAD系统，包括工艺参数设计、置口设计和浇注系统设计等模块。在CAE系统中，对铸件进行流场和温度场的模拟，以便校核和优化工艺设计。     

基于Pro/E汽车V8进气管逆向工程及其金属模设计

以汽车V8进气管为研究对象,探讨了逆向工程在模具设计中的应用.利用激光扫描仪对零件实体进行扫描取得点云数据,并用Imageware Surface软件对点云进行处理.采用Pro/E对已测的模型进行三维造型及模具设计.分析了这种形状复杂、型腔深、体积较大的零件的结构特点,针对重力浇注中易形成气孔、冷隔、壁穿、断芯等缺陷的工艺特性,重点考虑了金属模结构形式和浇注系统的开设.实际批量生产表明,上述缺陷能有效避免.     

消失模法试制6缸发动机铝进气管

介绍了消失模铸造6缸发动机铝进气管的工艺：砂箱内加隔板对解决细长管件变形无明最效果，通过减小振击力和缩短振击时间可消陈铸件娈形；单组分胶粘结的进气管娄模型浇注铝合金时．腔气化滞后，有产生冷隔的危险．大量生产时宜采用热熔胶粘结；铝合金消失模铸件常见缺陷有渣孔和微漏，通过改进浇注系统可以彻底消除渣孔．现有条件下无法彻底解决微漏。     

Casting of microstructured shark skin surfaces and possible applications on aluminum casting parts

Within the project "Functional Surfaces via Micro-and Nanoscaled Structures" which is part of the Cluster of Excellence "Integrative Production Technology" established and financed by the German Research Foundation (DFG),an investment casting process to produce 3-dimensional functional surfaces down to a structural size of 1μm on near-net-shape-casting parts has been developed.The common way to realize functional microstructures on metallic surfaces is to use laser ablation,electro discharge machining or micro milling.The handicap of these processes is their limited productivity.The approach of this project to raise the efficiency is to use the investment casting process to replicate microstructured surfaces by moulding from a laser-microstructured grand master pattern.The main research objective deals with the investigation of the single process steps of the investment casting process with regard to the moulding accuracy.Actual results concerning making of the wax pattern,suitability of ceramic mould and core materials for casting of an AlSi7Mg0.3 alloy as well as the knock-out behavior of the shells are presented.By using of the example of an intake manifold of a gasoline race car engine,a technical shark skin surface has been realized to reduce the drag of the intake air.The intake manifold consists of an air-restrictor with a defined inner diameter which is microstructured with technical shark skin riblets.For this reason the inner diameter cannot be drilled after casting and demands a very high accuracy of the casting part.A technology for the fabrication and demoulding of accurate microstructured castings are shown.Shrinkage factors of different moulding steps of the macroscopic casting part as well as the microscopic riblet structure have been examined as well.     

Identification of critical factors affecting shrinkage porosity in permanent mold casting using numerical simulations based on design of experiments

Vital process parameters affecting the size and location of a shrinkage pore defect in an aluminum alloy permanent mold casting of varying section thicknesses were sought. The aim was to either modify or eliminate the defect by manipulating those parameters so that the lower inlet manifold casting would pass a leak test. The study was carried out ‘off-line’ using numerical simulations of the casting process. This was because the just-in-time production schedule of the busy mass production automotive foundry involved did not allow for any interruptions to accommodate physical experimentation. In a relatively novel approach, the design of experiments (DOE) method was employed to limit the number of simulations required, realizing significant savings in both labor cost and the time spent to arrive at a solution. Mold coat thickness and mold temperature were identified as the vital two parameters from a field of five potential factors nominated by experienced foundry personnel. It was determined that a thicker mold coat and a higher mold temperature would modify temperature profiles in the casting in such a way as to move the shrinkage porosity away from the critical location to less critical regions in a dispersed form. This solution would assume greater importance in applications where there is only a limited supply of feed metal either due to geometric constraints or due to a conscious effort aimed at increasing material yield. As a consequence of incorporating the project recommendations, the foundry achieved a reduction of more than 13% in its annual scrap rate for the casting involved.     

铸轧机轧辊新型冷却循环水系统设计原理

在FATA HUNTER超型铸轧机的生产实践中,根据不同的铸轧速度和辊套壁厚,通过控制冷却水人口水温减少轧辊表面残留水分,来提高铸轧生产率和板坯质量,并设计出可控制冷却水人口温度的新型管道闭环循环轧辊冷却水系统．     

排气歧管铸件的铸造工艺设计与优化

针对排气歧管铸件孤立热节多,又无法设置冒口的情况,采用华铸工艺分析软件模拟铸件的凝固过程,预测缩孔、缩松缺陷出现的部位;采用铸件均衡凝固理论,设计浇注系统和冒口补缩系统,采用“宽、薄、短、斜”的冒口颈是充分利用石墨化膨胀自补缩作用的关键,采用该技术并优化相关工艺参数后,有效地克服了排气歧管铸件的缩孔、缩松缺陷,大幅度提高了铸件的工艺出品率和成品率,取得了显著的经济效益.     

康明斯6BT排气歧管铸件的生产技术

从造型、熔炼及热处理等方面介绍了康明斯6BT排气歧管铸件的主要生产工艺，并提出了铸造缺陷的解决措施。