实现铸铁件轻量化目标的五种方法
史蒂文做准备 | Waupaca铸造的 Corporate Average Fuel Economy (CAFE) standard is set to hit 54.2025年达到5英里/加仑, so it's no surprise the auto industry is aggressively pursuing ways to increase fuel efficiency. 的 汽车轻量化研究中心 Web site states that the use of lightweight materials in vehicles will significantly increase fuel efficiency and cut emissions. As the market takes a serious step towards increasing fuel economy, 材料替代的话题是最前沿的. Gray and ductile iron material is not exactly perceived as lightweight. But, use of this higher-strength iron, allows for design engineers to use less material. 现在我们来谈谈.
To achieve 轻量化 objects—regardless of material selection—early design collaboration with your supplier is crucial. Early design collaboration with your iron casting foundry that combines tooling engineering, metallurgical expertise and computer simulation will result in iron castings that may reduce weight, 降低总到岸成本, 增加质量, assure part consistency and meet or exceed performance requirements; all the items OEMs and Tier 1s seek from its suppliers. 在设计过程中做出的许多决定, specification and sourcing stages of an iron casting can lead to components that are lighter and stronger.
Here are five ways your iron casting supplier can help you achieve your 轻量化 objectives:
- 实施热处理并使用奥贝球铁(ADI)
- 重新定位浇口和立管位置
- 薄的铸铁件或铸铁壁
- 去掉一个芯
- 改变分型线的位置
这一切都始于 MAGMA®流量分析, an electronic simulation showing how molten iron flows and solidifies as it is poured into the casting mold. MAGMA®流量分析 allows foundry engineers to pre-determine iron flow and identify turbulence, 凝固, 温度, 而浇注问题关系到最终铸件的质量. 而MAGMA®流量分析本身并不是一个轻量级工具, it is a valuable tool that tells foundry engineers and their customers the options they have to achieve a lighter weight part including the five we outline here:
球墨铸铁的等温回火或热处理
A material selection upgrade to ADI over traditional ductile iron is a tool used for 轻量化. In particular ADI is two to four times stronger than standard ductile iron. Using ADI drives the weight of the casting down making it much lighter thanks to a reduction in structural mass requirements. 使用ADI时, strength requirements can be maintained while utilizing thinner sections, 为了全面减少组件的重量. 的 practical advantage to ADI is manufacturing cost, since it is much less expensive to produce.
重新定位门控和立管位置
If a MAGMA®流量分析 shows that an area of a mold will be difficult to fill resulting in porosity issues, it may be possible to reposition the gating or riser to overcome the porosity issues. Lowering the porosity in one or more areas of the casting can lead to there being more mass than needed in those areas. Removing mass and achieving an acceptable level of porosity will lead to a lighter part as long as that particular area is not necessary for strength or a machining location. Only through early collaboration can these questions be identified and answered.
减薄部分或壁
Most if not all part designs call out an acceptable level of porosity throughout the print. 再一次。, 使用MAGMA®流量分析, engineers can tell whether the iron flow will cause porosity to be above or below the acceptable level. Foundry engineers are not strangers to following porosity specifications. 的re are cast components where there is quite a bit of mass resulting in a porosity level that is far below what is specified on the print. If we get a commitment from the purchaser to allow a higher level of porosity, 但仍低于标准, 我们也许可以通过减少质量来减轻体重. 然而, this gets tricky because we may end up aggravating or creating more porosity in another area to achieve mass removal in this area. 再一次。, early collaboration in the casting design will make all the difference in the success of this 轻量化 effort.
移除或消除核心
This would take a commitment from the casting design engineer and the casting supplier early on in the design process. In some castings, the core simply cannot be removed due to internal features.
改变分割线的位置
Changing the location of a parting line is a fifth tool in the box that can be used for 轻量化. 想象一个铸铁花瓶垂直地立在桌子上. 的 top of the vase may have a diameter of two inches and as you move down the vase, 脖子缩窄到一英寸. 的n as you move further down the vase the belly of the vase opens to four inches. 在立式绿色砂型成型工艺中, in order to remove this vase from the sand without destroying the part, 在花瓶的脖子上必须用一个芯. 没有核心, material would have to be added to the vase so that the vase has the same diameter throughout. 这会使花瓶更重. 然而, 把花瓶放在一边, 改变分型线，使其沿着花瓶的曲线运行, 就不需要核心了. 的re would also be no need to add material to the vase allowing the vase to be lightweight.
再一次。, early design collaboration between the purchaser and the casting supplier will maximize 轻量化 outcomes and in best cases, 降低了零件的总到岸成本, 增加质量, 改善运行一致性和提高其性能. Involve your casting supplier early on in the design; you'll be happy you did.
