汽車鑄造技術(shù)發(fā)展

1、汽車鑄造技術(shù)發(fā)展趨勢(shì) Development Tendency of Automobile Foundry Technology2012年9月 北 京September 2012 Beijing一汽鑄造有限公司 侯 駿FAW Foundry Co., Ltd. HOU JUN內(nèi)容提要 引言 鑄造新材料應(yīng)用 鑄造新工藝應(yīng)用 鑄造工藝過程仿真模擬 鑄造工藝裝備集成應(yīng)用 鑄造節(jié)能、環(huán)保技術(shù)應(yīng)用鑄造先進(jìn)的成形制造技術(shù) Foundry-Advanced Materials Processing Technology鑄造是先進(jìn)的成形制造技術(shù) Foundry is advanced manufacturin

2、g by materials processing technology鑄造工藝的優(yōu)勢(shì)： Advantage of foundry technology 復(fù)雜零件 Complex part 一次成型 One-step molding 后續(xù)處理充分發(fā)揮材料的性能潛力 Subsequent treatment release property potential of material 鑄造工藝的難點(diǎn)： Difficulty of foundry technology 黑箱系統(tǒng) Black box system 工藝過程復(fù)雜，涉及流場(chǎng)、溫度場(chǎng)、應(yīng)力場(chǎng)等多重變量以及液態(tài)、結(jié)晶、凝固、相變等多形態(tài)轉(zhuǎn)化

3、 Process involving multivariate of flow field, temperature field, stress field etc. and polymorphic variation of liquid state, crystallization, solidification, phase transition etc. 中國(guó)世界汽車鑄造業(yè)的大國(guó) China-Giant of Automobile Foundry In the World 2010年全球鑄件產(chǎn)量9140萬噸，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 中國(guó)鑄件產(chǎn)量3960萬噸（其中灰鑄鐵1960萬噸，球鐵990萬噸，鑄鋼件530萬噸，有色金屬480萬噸），連續(xù)12年居全球之首。（2011年4150萬噸，增長(zhǎng)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%) 全球鑄件產(chǎn)量前十名的國(guó)家總產(chǎn)量8004萬噸，中國(guó)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%. 我國(guó)汽車鑄件2010年960萬噸，占鑄件總產(chǎn)量的24.2%。 Our automobile castings is 9.60 million tons in 2010, occupy 24.2% in total castings output. 單個(gè)工廠鑄件產(chǎn)量排名：

6、第1德國(guó)（7808噸），第2法國(guó)（4317噸），第3美國(guó)（4038噸），第10中國(guó)（1523噸）。 The castings output ranking of individual factory: the first is Germany, the second is France, the third is America, the tenth is China.現(xiàn)代汽車對(duì)鑄造技術(shù)發(fā)展的需求 Requirement of Modern Automobile for Foundry Technology Development 汽車是一種大眾化的耐用消費(fèi)商品，顧客追求“安全、節(jié)能、環(huán)保、舒

7、適” 。 Automobile- “safety, save energy, environmental protection, comfort” 汽車鑄件的發(fā)展方向要滿足汽車產(chǎn)品的需求：“輕量化、強(qiáng)韌化、精確化、集成化”。 Automobile castings-“l(fā)ight weighting, strengthening and toughening, precision, integration” 鑄造技術(shù)要滿足可持續(xù)發(fā)展需要：“高效、節(jié)能、環(huán)保、智能化”，綠色鑄造，資源節(jié)約，環(huán)境友好。 Foundry technology-“high efficiency, save energy,

8、 environmental protection, intelligent” .典型汽車鑄件的應(yīng)用 Application on Automobile Castings汽油機(jī)缸蓋（鋁合金）Gasoline engine head (aluminum alloy)柴油機(jī)缸體（蠕鐵）Diesel engine block (CGI)汽油機(jī)缸體（鋁合金）Gasoline engine block (aluminum alloy)汽油機(jī)缸體（鋁合金）Gasoline engine block (aluminum alloy)曲軸（球鐵）Crank shaft (ductile iron)支架（鋁合金

9、）Support (aluminum alloy)連接板（鋁合金）Junction plate (aluminum alloy)典型汽車鑄件的應(yīng)用 Application on Automobile Castings變速器殼體（鋁合金）Transmission housing (aluminum alloy)變速器殼體（鋁合金）Transmission housing (aluminum alloy)離合器殼體（鋁合金）Clutch housing (aluminum alloy)變速器殼體（鎂合金）Transmission housing (magnesium alloy)典型汽車鑄件的應(yīng)用

10、 Application on Automobile Castings車門框架（鎂合金）Door frame (magnesium alloy)儀表盤骨架（鎂合金）Instrument panel framework (magnesium alloy)后車門（鋁合金）Rear door (aluminum alloy)座椅骨架（鎂合金）Chair frame (magnesium alloy)內(nèi)容提要 引言 鑄造新材料應(yīng)用 鑄造新工藝應(yīng)用 鑄造工藝過程仿真模擬 鑄造工藝裝備集成應(yīng)用 鑄造節(jié)能、環(huán)保技術(shù)應(yīng)用ADI（Austempered Ductile Iron）的應(yīng)用 Application

11、of ADI用做汽車鑄件材料可以代替鑄鋼、鍛鋼、鍛鋁件Instead of casting steel, wrought steel, wrought aluminum ADI（Austempered Ductile Iron）的應(yīng)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 技術(shù)標(biāo)準(zhǔn) technology StandardADI（Austempered Ductile Iron）的應(yīng)用 Application of ADI（資料來源：美國(guó)AP） 某卡車制造商采用ADI代替鑄鋼件，零

13、件重量由630kg減到380kg，減重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）的應(yīng)用 Application of ADIADI是一種“綠色”材料。ADI is a “green” material. 其蘊(yùn)含能量比低碳鋼和低合金鋼低40%，疲勞性能比球鐵和鋁合金好很多。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. （資料來源： 美國(guó)AP） 蠕墨鑄鐵（CGI）的應(yīng)用 Application of CGICGI具有比普通灰鑄鐵和鋁合金至少高75%的抗拉強(qiáng)度，高45%的彈性模量和高近一倍的疲勞強(qiáng)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是制造大馬力、高爆發(fā)壓力發(fā)動(dòng)機(jī)缸體、缸蓋的首選材料。 CGI is the first choice material to manufacture high power, outbreak of high press engine block and head.采用CGI制造發(fā)動(dòng)機(jī)缸體、缸蓋，能提高發(fā)動(dòng)機(jī)的性能、燃油效率和耐久性，同時(shí)減輕發(fā)動(dòng)機(jī)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. 蠕墨鑄鐵（CGI）的應(yīng)用 Application of CGI（資料來源：SINTERCAST） 過共晶Al-Si合金的應(yīng)用 Application of Hypereutectic Al-S

17、i Alloy過共晶Al-Si合金具有熱膨脹系數(shù)小、密度小、耐磨、耐蝕、高溫力學(xué)性能好的優(yōu)點(diǎn)。low thermal expansion, low density, wear-resisting, anti-corrosion, good high temperature mechanical property.鋁缸體鑲鑄過共晶Al-Si合金缸套Engine block cast in hypereutectic Ai-Si alloy liner減小缸套與缸體熱膨脹率的差別 Reducing difference of thermal expansion between liner and

18、engine block改善導(dǎo)熱能力2-3倍 Better 2-3 times on capacity of heat-transmission提高耐磨性能 Enhance wear-resisting property減輕零件重量12% Reducing 12% on part weight塊狀初晶硅和桿狀共晶硅 primary crystal silicon and eutectic silicon內(nèi)容提要 引言 鑄造新材料應(yīng)用 鑄造新工藝應(yīng)用 鑄造工藝過程仿真模擬 鑄造工藝裝備集成應(yīng)用 鑄造節(jié)能、環(huán)保技術(shù)應(yīng)用鋁鎂復(fù)合壓鑄缸體 Engine Block of Al-Mg Composite

19、 缸套、水套和主軸承座設(shè)計(jì)為一體，采用鋁合金鑄造成型，并作為鑲件在壓鑄鎂合金缸體時(shí)復(fù)合成一體。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 .具有機(jī)械強(qiáng)度高、耐磨性和耐熱性好、重量輕的優(yōu)點(diǎn)，滿足發(fā)動(dòng)機(jī)性能的要求精密鑄造精確化和集成化解決方案 Precision Casting Pr

20、ecision and Integration Solution 應(yīng)用硅溶膠-水玻璃復(fù)合型殼精鑄生產(chǎn)工藝。Application of ludox-sodium silicate compound shell precision production process.滿足汽車高端精鑄件對(duì)表面質(zhì)量、尺寸精度的高質(zhì)量要求，以低成本生產(chǎn)高質(zhì)量精鑄件。high surface quality, dimension precision and low cost .零件集成化設(shè)計(jì)，集成沖壓、焊接和裝配三道工序，一次成形 integration punch, welding and assembling t

21、hree procedures into one .減少工序，減輕重量，降低成本 Reducing procedures, weight and cost（資料來源：DFIC） 高真空壓鑄 High vacuum Die casting壓鑄一種最經(jīng)濟(jì)的鋁鑄造工藝 Die casting-the most economic casting process 工藝局限性普通壓鑄件含有較多氣體，不能通過熱處理（T4-T7）提高機(jī)械性能；不能做焊接組合. Conventional die castings have more gas, cant be enhanced mechanical proper

22、ty through heat treatment (T4-T7); cant be welded. 高真空壓鑄-減少鋁液充填時(shí)的湍流和氧化，大幅度減少鑄件的氣孔含量。生產(chǎn)高延伸率、可熱處理、可焊接、鉚接的汽車結(jié)構(gòu)件。如：車門、副車架、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.半固態(tài)鑄造 Semi-solid Casting 使用半固態(tài)漿料，在壓力下充填，或采用Thixoforming方法生產(chǎn)。 To adopt SMM slurry, filling in pressure or adopt Thixoforming process to product.生產(chǎn)效率高，能源消耗少（節(jié)能35%

24、），模具壽命長(zhǎng)。High production efficiency, low energy expense ( save energy 35%), long tooling life. 鑄件組織致密，氣孔夾雜缺陷少，機(jī)械強(qiáng)度高，特別適合制造高強(qiáng)度的汽車結(jié)構(gòu)件，可以代替重力鑄造或鍛件。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.擠壓鑄造（液態(tài)擠鍛復(fù)合成形） Squeezing Casting (Liquid Squeeze and Forge Composite Forming) 合金液在壓力作用下低速充型、凝固并發(fā)生微量塑性變形。 alloy liquid fill with low speed, solidify under pressure and emerge few plastic deformation.鑄件表面光潔、尺寸精度高、組織致密、機(jī)械性能良好，適合生產(chǎn)厚壁鑄件，如：車輪、副車架、轉(zhuǎn)向節(jié)和控制臂等底盤結(jié)構(gòu)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. 材料綜合力學(xué)性能提高，零件可減重20-60%左右，成本遠(yuǎn)低于鍛鋁。 mechanical property increase, weight of part can be reduced 20-60

27、%, cost is much lower than wrought casting. 內(nèi)容提要 引言 鑄造新材料應(yīng)用 鑄造新工藝應(yīng)用 鑄造工藝過程仿真模擬 鑄造工藝裝備集成應(yīng)用 鑄造節(jié)能、環(huán)保技術(shù)應(yīng)用制芯過程計(jì)算機(jī)仿真 Simulation of Core-making Processl 復(fù)雜鑄件的生產(chǎn)需要使用砂芯，目前大量使用的冷芯盒制芯工藝，通過冷芯盒制芯設(shè)備和芯盒（模具），經(jīng)過射砂、硬化、吹氣清洗等工藝過程。 Cold-box process, shooting sand, hardening, blowing and cleaning etc. l 制芯過程的仿真模擬可以輔助模具設(shè)計(jì)

28、，提高砂芯合格率和生產(chǎn)效率，減少砂芯的修補(bǔ)，降低生產(chǎn)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離散顆粒，空氣是連續(xù)的介質(zhì)，射砂的過程是多相流動(dòng)，涉及到空氣動(dòng)力學(xué)和顆粒之間的摩擦力學(xué)?！胺€(wěn)態(tài)”的砂芯是透氣的幾何體。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. 制芯過程計(jì)算機(jī)仿真模擬 Simulation of Core-making Process制芯過程計(jì)算機(jī)仿真模擬 Simulation of Core-making Process實(shí)際生產(chǎn)砂芯（左）與仿真模擬結(jié)果（右）的對(duì)比actual production core (left) and simulation result (right)（資料來源：ASK

30、）l FORD、GM、TOYOTA、MAZDA、NISSAN、VOLVO等公司在使用ARENA-FLOW軟件。內(nèi)容提要 引言 鑄造新材料應(yīng)用 鑄造新工藝應(yīng)用 鑄造工藝過程仿真模擬 鑄造工藝裝備集成應(yīng)用 鑄造節(jié)能、環(huán)保技術(shù)應(yīng)用鑄造生產(chǎn)自動(dòng)化-智能化生產(chǎn)單元 Foundry Manufacture AutomationIntelligent Production Unit 機(jī)器人熔化車間（ARMS系統(tǒng)）實(shí)現(xiàn)電爐熔煉的自動(dòng)化，由機(jī)器人代替工人進(jìn)行加料、控溫、扒渣、測(cè)溫、取樣、出鐵水等一系列惡劣環(huán)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.（資料來源：美國(guó)Inductotherm） 鑄造生產(chǎn)自動(dòng)化-智能化生產(chǎn)單元 Foundry Manufacture AutomationIntelligent Production Unit 高壓鑄造單元 Die-casting Unitl 由壓鑄機(jī)、保溫爐、噴涂機(jī)、機(jī)器人、沖邊機(jī)、鋸床組成壓鑄島，生產(chǎn)發(fā)動(dòng)機(jī)鋁缸體。Die-casting machine, holding f

32、urnace, coating machine, robot, trimming machine, sawing machine compose die-casting island. l 自動(dòng)完成噴涂料、下缸套、合模、壓射、取件，冷卻、鋸澆口、沖邊、修毛刺、裝箱等工藝循環(huán)。 Automatic complete coating, placing liner, shooting, taking casting, cooling, saw gate, trimming, burr off etc. l 實(shí)現(xiàn)從鋁液到缸體毛坯的自動(dòng)化過程。Unmanned production from molte

33、n metal to cylinder block casting.（資料來源：德國(guó)FRECH） 鑄造生產(chǎn)自動(dòng)化-智能化生產(chǎn)單元 Foundry Manufacture AutomationIntelligent Production Unit 制芯中心 Core-making Center由冷芯盒制芯機(jī)、機(jī)器人、組芯夾具、涂料機(jī)、烘干爐、立體倉(cāng)庫(kù)組成制芯中心，完成混砂、制芯、去飛邊毛刺、組裝、涂料、烘干、貯存等一系列工序。 complete sand mixing, core-making, rag and burr off, assembly, coating, drying, stora

34、ge etc.（資料來源：德國(guó)LAEMPE）鑄造生產(chǎn)自動(dòng)化-柔性精整單元 Foundry Manufacture AutomationFlexibility Finishing Unit全自動(dòng)實(shí)現(xiàn)多品種鑄件的精整，包括鑄件清理的所有工序：上料、下料、除芯、切澆冒口、去飛邊毛刺、檢查、貯存等。由機(jī)器人代替工人進(jìn)行鑄件飛邊、毛刺的打磨，loading, unloading, decoring, degating, deburring , inspection, storage etc. Robot instead of worker. （資料來源：MAUS） l 上、下料機(jī)器人l 除芯3D震砂機(jī)l

35、 切澆冒口高速帶鋸機(jī)l 去飛邊毛刺機(jī)器人夾持+多動(dòng)力頭五軸加工中心（金剛砂輪、銑刀）l 檢查視頻檢測(cè)，激光打二維碼l 貯存分類存貯、查詢鑄造生產(chǎn)自動(dòng)化-柔性精整單元 Foundry Manufacture AutomationFlexibility Finishing Unit上料位置帶鋸機(jī)切橫澆道除芯機(jī)磨、鑿、銑，鑄件精整去除飛邊毛刺返回料收集搬運(yùn)機(jī)器人澆口鋸床CNC帶鋸機(jī)，切澆冒口下料位置操控臺(tái)供電及信息網(wǎng)絡(luò)視頻定位系統(tǒng)（資料來源：MOESSNER）內(nèi)容提要 引言 鑄造新材料應(yīng)用 鑄造新工藝應(yīng)用 鑄造工藝過程仿真模擬 鑄造工藝裝備集成應(yīng)用 鑄造節(jié)能、環(huán)保技術(shù)應(yīng)用循環(huán)經(jīng)濟(jì)的探索砂里淘“金”

36、Recycle Economy 通過貿(mào)易方式把其他企業(yè)的廢棄物或副產(chǎn)品作為本企業(yè)的廉價(jià)生產(chǎn)原料，建立工業(yè)橫生和代謝生態(tài)鏈關(guān)系，最終實(shí)現(xiàn)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”-熔化爐除塵廢灰中提煉金屬鋅。refine zinc from ash

37、 of dedusting of melting furnace. 汽車生產(chǎn)大量使用鍍鋅鋼板，鋼板沖壓的邊角余料是黑色鑄造的優(yōu)質(zhì)原材料。scrap steel is high quality raw material of iron casting.黑色鑄造熔化爐產(chǎn)生的含鋅粉塵是一種有毒固體廢棄物，以一汽鑄造為例，電爐粉塵的含鋅量高達(dá)60%，沖天爐粉塵的含鋅量高達(dá)30%。以前采用深埋處理，占用土地，資源浪費(fèi)。 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. 金屬鋅是工、農(nóng)業(yè)重要的原材料，全世界年消耗鋅近百萬噸，高品位的閃鋅礦儲(chǔ)量在我國(guó)已經(jīng)越來越少，屬于匱乏礦產(chǎn)。含鋅粉塵再生利用，變廢為寶，造福人類。Zinc is important raw material of industry and agriculture. Dust with zinc recycle, turn wasted into wealth, benefit mankind. 采用一種零排放、無公害的堿法制鋅提取技術(shù)，金屬鋅粉的純度為99.9%以上，回收率達(dá)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%. 舊砂的再生利用 Sand Reclamation 粘土砂造型（潮模砂）工藝具有成本低、適合大批量生產(chǎn)等優(yōu)點(diǎn)，在汽車鑄造業(yè)占有很大比例。生產(chǎn)缸體、缸蓋鑄件，大多采用有機(jī)樹脂制作砂芯，以膨潤(rùn)土作為粘結(jié)劑的潮模砂和有機(jī)樹脂作為粘結(jié)劑的芯砂在落砂工序相互混合，簡(jiǎn)單的廢棄，

40、對(duì)環(huán)境和資源都造成危害。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. 單一樹脂砂再生技術(shù)已日臻成熟?！盎旌仙啊痹偕夹g(shù)提出新的挑戰(zhàn)。 Single resin sand recycle technology has matured graduall

41、y. “mixed sand” recycle technology put forward new challenge. 當(dāng)今流行的技術(shù)路徑：“熱焙燒”+“機(jī)械磨擦” Popular technology route: “hot method” + ”mechanical grinding”HALBERG GUSS 采用“熱法+機(jī)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“機(jī)械磨擦”，用于制造曲軸箱砂芯（冷芯盒）。FRITZ WINTER 采用“機(jī)械磨擦”，用于制造曲軸箱砂芯（冷芯盒）DAIMLER 采用“機(jī)械磨擦”，用于制造曲軸箱砂芯（

42、冷芯盒）舊砂的回收率可以達(dá)到75%（100公斤舊砂回收70公斤再生砂和5公斤膨潤(rùn)土細(xì)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、熱處理“三合一”工藝 Decoring, Sand Reclamation, Heat Treatment 3-in-1 process 在同一臺(tái)設(shè)備里完成鋁鑄件的除砂、砂再生和熱處理三個(gè)工序。鑄件澆注、凝固后送進(jìn)爐子，砂芯中的有機(jī)黏結(jié)劑在420以上燃燒，砂芯潰散，爐子內(nèi)部的空氣流動(dòng)形成負(fù)壓，使砂子從鑄件內(nèi)部的水套、油道等內(nèi)腔剝離; Binder in c