汽车铸造技术发展

1、汽车铸造技术发展趋势 Development Tendency of Automobile Foundry Technology2012年9月 北 京September 2012 Beijing一汽铸造有限公司 侯 骏FAW Foundry Co., Ltd. HOU JUN内容提要 引言 铸造新材料应用 铸造新工艺应用 铸造工艺过程仿真模拟 铸造工艺装备集成应用 铸造节能、环保技术应用铸造先进的成形制造技术 Foundry-Advanced Materials Processing Technology铸造是先进的成形制造技术 Foundry is advanced manufacturin

2、g by materials processing technology铸造工艺的优势： Advantage of foundry technology 复杂零件 Complex part 一次成型 One-step molding 后续处理充分发挥材料的性能潜力 Subsequent treatment release property potential of material 铸造工艺的难点： Difficulty of foundry technology 黑箱系统 Black box system 工艺过程复杂，涉及流场、温度场、应力场等多重变量以及液态、结晶、凝固、相变等多形态转化

3、 Process involving multivariate of flow field, temperature field, stress field etc. and polymorphic variation of liquid state, crystallization, solidification, phase transition etc. 中国世界汽车铸造业的大国 China-Giant of Automobile Foundry In the World 2010年全球铸件产量9140万吨，比2009年增加13.7%。 The global castings outpu

4、t is 91.4 million tons in 2010, which is increased by 13.7% than in 2009 中国铸件产量3960万吨（其中灰铸铁1960万吨，球铁990万吨，铸钢件530万吨，有色金属480万吨），连续12年居全球之首。（2011年4150万吨，增长4.8%）The Chinese castings output is 39.60 million tons , which is biggest output in the world for 12 consecutive years. ( 41.50 million tons in 2011

5、, increased by 4.8%) 全球铸件产量前十名的国家总产量8004万吨，中国占49.5%。The total output of in the top ten nation of global castings is 80.04 million tons, Chinese output occupy 49.5%. 我国汽车铸件2010年960万吨，占铸件总产量的24.2%。 Our automobile castings is 9.60 million tons in 2010, occupy 24.2% in total castings output. 单个工厂铸件产量排名：

6、第1德国（7808吨），第2法国（4317吨），第3美国（4038吨），第10中国（1523吨）。 The castings output ranking of individual factory: the first is Germany, the second is France, the third is America, the tenth is China.现代汽车对铸造技术发展的需求 Requirement of Modern Automobile for Foundry Technology Development 汽车是一种大众化的耐用消费商品，顾客追求“安全、节能、环保、舒

7、适” 。 Automobile- “safety, save energy, environmental protection, comfort” 汽车铸件的发展方向要满足汽车产品的需求：“轻量化、强韧化、精确化、集成化”。 Automobile castings-“light weighting, strengthening and toughening, precision, integration” 铸造技术要满足可持续发展需要：“高效、节能、环保、智能化”，绿色铸造，资源节约，环境友好。 Foundry technology-“high efficiency, save energy,

8、 environmental protection, intelligent” .典型汽车铸件的应用 Application on Automobile Castings汽油机缸盖（铝合金）Gasoline engine head (aluminum alloy)柴油机缸体（蠕铁）Diesel engine block (CGI)汽油机缸体（铝合金）Gasoline engine block (aluminum alloy)汽油机缸体（铝合金）Gasoline engine block (aluminum alloy)曲轴（球铁）Crank shaft (ductile iron)支架（铝合金

9、）Support (aluminum alloy)连接板（铝合金）Junction plate (aluminum alloy)典型汽车铸件的应用 Application on Automobile Castings变速器壳体（铝合金）Transmission housing (aluminum alloy)变速器壳体（铝合金）Transmission housing (aluminum alloy)离合器壳体（铝合金）Clutch housing (aluminum alloy)变速器壳体（镁合金）Transmission housing (magnesium alloy)典型汽车铸件的应用

10、 Application on Automobile Castings车门框架（镁合金）Door frame (magnesium alloy)仪表盘骨架（镁合金）Instrument panel framework (magnesium alloy)后车门（铝合金）Rear door (aluminum alloy)座椅骨架（镁合金）Chair frame (magnesium alloy)内容提要 引言 铸造新材料应用 铸造新工艺应用 铸造工艺过程仿真模拟 铸造工艺装备集成应用 铸造节能、环保技术应用ADI（Austempered Ductile Iron）的应用 Application

11、of ADI用做汽车铸件材料可以代替铸钢、锻钢、锻铝件Instead of casting steel, wrought steel, wrought aluminum ADI（Austempered Ductile Iron）的应用 Application of ADIISO 17804Issued 2005SAE J2477Issued 2003Revised 2004ASTMA897/A897MReapproved 2011CHINA StandardGB/T 2473Issued 2009800-500-10750-500-11750-500-11800-500-10900-600-0

12、8900-650-09900-650-09900-600-081050-700-061050-750-071050-750-071050-700-061200-850-031200-850-041200-850-041200-850-031400-1100-011400-1100-021400-1100-021400-1100-011600-1300-011600-1300-01ADI 技术标准 technology StandardADI（Austempered Ductile Iron）的应用 Application of ADI（资料来源：美国AP） 某卡车制造商采用ADI代替铸钢件，零

13、件重量由630kg减到380kg，减重40%。The truck manufacture adopt ADI instead of casting steel, the weight of casting reduce from 630Kg to 380kg, reduce by 40%.ADI（Austempered Ductile Iron）的应用 Application of ADIADI是一种“绿色”材料。ADI is a “green” material. 其蕴含能量比低碳钢和低合金钢低40%，疲劳性能比球铁和铝合金好很多。Its embodied energy is lower 4

14、0% than mild steel and low alloy steel, its fatigue property is much better than ductile iron and aluminum alloy. （资料来源： 美国AP） 蠕墨铸铁（CGI）的应用 Application of CGICGI具有比普通灰铸铁和铝合金至少高75%的抗拉强度，高45%的弹性模量和高近一倍的疲劳强度。Tensile strength of CGI is higher 75% than that of gray iron and aluminum alloy; modulus of ela

15、sticity of CGI is higher 45% than that of those; fatigue strength is higher nearly 100% than that of those.CGI是制造大马力、高爆发压力发动机缸体、缸盖的首选材料。 CGI is the first choice material to manufacture high power, outbreak of high press engine block and head.采用CGI制造发动机缸体、缸盖，能提高发动机的性能、燃油效率和耐久性，同时减轻发动机的重量，降低噪音和排放。To a

16、dopt CGI material to manufacture engine block and head, high engine property, high fuel efficiency and high durability can be available as well as lightening weight of engine, reducing noise and exhaust. 蠕墨铸铁（CGI）的应用 Application of CGI（资料来源：SINTERCAST） 过共晶Al-Si合金的应用 Application of Hypereutectic Al-S

17、i Alloy过共晶Al-Si合金具有热膨胀系数小、密度小、耐磨、耐蚀、高温力学性能好的优点。low thermal expansion, low density, wear-resisting, anti-corrosion, good high temperature mechanical property.铝缸体镶铸过共晶Al-Si合金缸套Engine block cast in hypereutectic Ai-Si alloy liner减小缸套与缸体热膨胀率的差别 Reducing difference of thermal expansion between liner and

18、engine block改善导热能力2-3倍 Better 2-3 times on capacity of heat-transmission提高耐磨性能 Enhance wear-resisting property减轻零件重量12% Reducing 12% on part weight块状初晶硅和杆状共晶硅 primary crystal silicon and eutectic silicon内容提要 引言 铸造新材料应用 铸造新工艺应用 铸造工艺过程仿真模拟 铸造工艺装备集成应用 铸造节能、环保技术应用铝镁复合压铸缸体 Engine Block of Al-Mg Composite

19、 缸套、水套和主轴承座设计为一体，采用铝合金铸造成型，并作为镶件在压铸镁合金缸体时复合成一体。Liner, water jacket and main bearing block integrated design, adopt aluminum alloy casting , which being as insert a composition with engine block whilst die-casting magnesium alloy .具有机械强度高、耐磨性和耐热性好、重量轻的优点，满足发动机性能的要求精密铸造精确化和集成化解决方案 Precision Casting Pr

20、ecision and Integration Solution 应用硅溶胶-水玻璃复合型壳精铸生产工艺。Application of ludox-sodium silicate compound shell precision production process.满足汽车高端精铸件对表面质量、尺寸精度的高质量要求，以低成本生产高质量精铸件。high surface quality, dimension precision and low cost .零件集成化设计，集成冲压、焊接和装配三道工序，一次成形 integration punch, welding and assembling t

21、hree procedures into one .减少工序，减轻重量，降低成本 Reducing procedures, weight and cost（资料来源：DFIC） 高真空压铸 High vacuum Die casting压铸一种最经济的铝铸造工艺 Die casting-the most economic casting process 工艺局限性普通压铸件含有较多气体，不能通过热处理（T4-T7）提高机械性能；不能做焊接组合. Conventional die castings have more gas, cant be enhanced mechanical proper

22、ty through heat treatment (T4-T7); cant be welded. 高真空压铸-减少铝液充填时的湍流和氧化，大幅度减少铸件的气孔含量。生产高延伸率、可热处理、可焊接、铆接的汽车结构件。如：车门、副车架、A立柱、B立柱、C立柱等 High vacuum die casting-reducing turbulence and oxidation whilst molten metal feed, significantly reducing amount of air of casting. It can be used to manufacture automo

23、bile structure part with high elongation, heat-treatable, weldable, riveting. Such as car door, sub frame, A column, B column, C column etc.半固态铸造 Semi-solid Casting 使用半固态浆料，在压力下充填，或采用Thixoforming方法生产。 To adopt SMM slurry, filling in pressure or adopt Thixoforming process to product.生产效率高，能源消耗少（节能35%

24、），模具寿命长。High production efficiency, low energy expense ( save energy 35%), long tooling life. 铸件组织致密，气孔夹杂缺陷少，机械强度高，特别适合制造高强度的汽车结构件，可以代替重力铸造或锻件。Compact casting structure, few air hole and slag detect, high mechanical property, manufacture high strength automobile structure part, can be instead of gra

25、vity casting or wrought part.挤压铸造（液态挤锻复合成形） Squeezing Casting (Liquid Squeeze and Forge Composite Forming) 合金液在压力作用下低速充型、凝固并发生微量塑性变形。 alloy liquid fill with low speed, solidify under pressure and emerge few plastic deformation.铸件表面光洁、尺寸精度高、组织致密、机械性能良好，适合生产厚壁铸件，如：车轮、副车架、转向节和控制臂等底盘结构件 。finish surface,

26、 high dimension precision, compact structure, fine mechanical property, being appropriate for production thick wall part, such as wheel, sub frame, knuckle and control arm etc. chassis structure part. 材料综合力学性能提高，零件可减重20-60%左右，成本远低于锻铝。 mechanical property increase, weight of part can be reduced 20-60

27、%, cost is much lower than wrought casting. 内容提要 引言 铸造新材料应用 铸造新工艺应用 铸造工艺过程仿真模拟 铸造工艺装备集成应用 铸造节能、环保技术应用制芯过程计算机仿真 Simulation of Core-making Processl 复杂铸件的生产需要使用砂芯，目前大量使用的冷芯盒制芯工艺，通过冷芯盒制芯设备和芯盒（模具），经过射砂、硬化、吹气清洗等工艺过程。 Cold-box process, shooting sand, hardening, blowing and cleaning etc. l 制芯过程的仿真模拟可以辅助模具设计

28、，提高砂芯合格率和生产效率，减少砂芯的修补，降低生产成本。increase core yield and production efficiency, reduce core repair and production cost. l 芯砂是具有一定尺寸分布的离散颗粒，空气是连续的介质，射砂的过程是多相流动，涉及到空气动力学和颗粒之间的摩擦力学。“稳态”的砂芯是透气的几何体。Core is disperse particle with regular dimension distribution, air is continuous medium, shooting sand is multi

29、phase flowing, involving aerodynamics and rubbing mechanics among particles. “steady state” core is ventilate geometry. 制芯过程计算机仿真模拟 Simulation of Core-making Process制芯过程计算机仿真模拟 Simulation of Core-making Process实际生产砂芯（左）与仿真模拟结果（右）的对比actual production core (left) and simulation result (right)（资料来源：ASK

30、）l FORD、GM、TOYOTA、MAZDA、NISSAN、VOLVO等公司在使用ARENA-FLOW软件。内容提要 引言 铸造新材料应用 铸造新工艺应用 铸造工艺过程仿真模拟 铸造工艺装备集成应用 铸造节能、环保技术应用铸造生产自动化-智能化生产单元 Foundry Manufacture AutomationIntelligent Production Unit 机器人熔化车间（ARMS系统）实现电炉熔炼的自动化，由机器人代替工人进行加料、控温、扒渣、测温、取样、出铁水等一系列恶劣环境中的操作。electric furnace melt automation, robot can cha

31、rge, control temperature, deslagging, test temperature, take sample, tilting molten iron etc.instead of worker.（资料来源：美国Inductotherm） 铸造生产自动化-智能化生产单元 Foundry Manufacture AutomationIntelligent Production Unit 高压铸造单元 Die-casting Unitl 由压铸机、保温炉、喷涂机、机器人、冲边机、锯床组成压铸岛，生产发动机铝缸体。Die-casting machine, holding f

32、urnace, coating machine, robot, trimming machine, sawing machine compose die-casting island. l 自动完成喷涂料、下缸套、合模、压射、取件，冷却、锯浇口、冲边、修毛刺、装箱等工艺循环。 Automatic complete coating, placing liner, shooting, taking casting, cooling, saw gate, trimming, burr off etc. l 实现从铝液到缸体毛坯的自动化过程。Unmanned production from molte

33、n metal to cylinder block casting.（资料来源：德国FRECH） 铸造生产自动化-智能化生产单元 Foundry Manufacture AutomationIntelligent Production Unit 制芯中心 Core-making Center由冷芯盒制芯机、机器人、组芯夹具、涂料机、烘干炉、立体仓库组成制芯中心，完成混砂、制芯、去飞边毛刺、组装、涂料、烘干、贮存等一系列工序。 complete sand mixing, core-making, rag and burr off, assembly, coating, drying, stora

34、ge etc.（资料来源：德国LAEMPE）铸造生产自动化-柔性精整单元 Foundry Manufacture AutomationFlexibility Finishing Unit全自动实现多品种铸件的精整，包括铸件清理的所有工序：上料、下料、除芯、切浇冒口、去飞边毛刺、检查、贮存等。由机器人代替工人进行铸件飞边、毛刺的打磨，loading, unloading, decoring, degating, deburring , inspection, storage etc. Robot instead of worker. （资料来源：MAUS） l 上、下料机器人l 除芯3D震砂机l

35、 切浇冒口高速带锯机l 去飞边毛刺机器人夹持+多动力头五轴加工中心（金刚砂轮、铣刀）l 检查视频检测，激光打二维码l 贮存分类存贮、查询铸造生产自动化-柔性精整单元 Foundry Manufacture AutomationFlexibility Finishing Unit上料位置带锯机切横浇道除芯机磨、凿、铣，铸件精整去除飞边毛刺返回料收集搬运机器人浇口锯床CNC带锯机，切浇冒口下料位置操控台供电及信息网络视频定位系统（资料来源：MOESSNER）内容提要 引言 铸造新材料应用 铸造新工艺应用 铸造工艺过程仿真模拟 铸造工艺装备集成应用 铸造节能、环保技术应用循环经济的探索砂里淘“金”

36、Recycle Economy 通过贸易方式把其他企业的废弃物或副产品作为本企业的廉价生产原料，建立工业横生和代谢生态链关系，最终实现污染“零排放”。To obtain cheap materials from waste and by-product of other enterprise through trade, establish lateral grow and ecological chain relationship , realize “zero emission” of pollution. 砂里淘“金”-熔化炉除尘废灰中提炼金属锌。refine zinc from ash

37、 of dedusting of melting furnace. 汽车生产大量使用镀锌钢板，钢板冲压的边角余料是黑色铸造的优质原材料。scrap steel is high quality raw material of iron casting.黑色铸造熔化炉产生的含锌粉尘是一种有毒固体废弃物，以一汽铸造为例，电炉粉尘的含锌量高达60%，冲天炉粉尘的含锌量高达30%。以前采用深埋处理，占用土地，资源浪费。 For example, the first plant of FAW Foundry Ltd. , whose electric furnace dust include zinc 6

38、0% of dust, whose cupola include zinc 30% of dust. 金属锌是工、农业重要的原材料，全世界年消耗锌近百万吨，高品位的闪锌矿储量在我国已经越来越少，属于匮乏矿产。含锌粉尘再生利用，变废为宝，造福人类。Zinc is important raw material of industry and agriculture. Dust with zinc recycle, turn wasted into wealth, benefit mankind. 采用一种零排放、无公害的碱法制锌提取技术，金属锌粉的纯度为99.9%以上，回收率达到80%以上。 a

39、kind of zero emission, non-polluted alkaline method extract zinc technology can be available zinc with above 99.9% fineness and recovery rate can be reached above 80%. 旧砂的再生利用 Sand Reclamation 粘土砂造型（潮模砂）工艺具有成本低、适合大批量生产等优点，在汽车铸造业占有很大比例。生产缸体、缸盖铸件，大多采用有机树脂制作砂芯，以膨润土作为粘结剂的潮模砂和有机树脂作为粘结剂的芯砂在落砂工序相互混合，简单的废弃，

40、对环境和资源都造成危害。Green sand process occupy great proportion in automobile foundry . Core with organic resin which mutual mix with bentonite of green sand when sand shaking out, waste damage environment and resource. 单一树脂砂再生技术已日臻成熟。“混合砂”再生技术提出新的挑战。 Single resin sand recycle technology has matured graduall

41、y. “mixed sand” recycle technology put forward new challenge. 当今流行的技术路径：“热焙烧”+“机械磨擦” Popular technology route: “hot method” + ”mechanical grinding”HALBERG GUSS 采用“热法+机械磨擦”，再生砂100%用于冷芯盒制芯（包括油道、水套芯）。EISENWERKE BRHL 采用“机械磨擦”，用于制造曲轴箱砂芯（冷芯盒）。FRITZ WINTER 采用“机械磨擦”，用于制造曲轴箱砂芯（冷芯盒）DAIMLER 采用“机械磨擦”，用于制造曲轴箱砂芯（

42、冷芯盒）旧砂的回收率可以达到75%（100公斤旧砂回收70公斤再生砂和5公斤膨润土细粉料）。Reclaimed sand recovery can reach 75% ( 100kg used sand recover 70kg reclaimed sand and 5kg bentonite fine power)除砂、砂再生、热处理“三合一”工艺 Decoring, Sand Reclamation, Heat Treatment 3-in-1 process 在同一台设备里完成铝铸件的除砂、砂再生和热处理三个工序。铸件浇注、凝固后送进炉子，砂芯中的有机黏结剂在420以上燃烧，砂芯溃散，炉子内部的空气流动形成负压，使砂子从铸件内部的水套、油道等内腔剥离; Binder in c