Improvement on Die Casting for Aluminum Alloy Cylinder Blocks of Automobile Engines (Part One)
Abstract
As an important part of a car, the engine can provide enough power for the car, which has a great impact on the environmental protection and safety of the car. In addition, compared with the traditional die casting process of aluminum alloy cylinder blocks, the improved cylinder block die casting process can effectively avoid a series of problems, for example oil leakage in automobile engines, and improve the reliability and safety of automobile operation. The improvement measures of die casting of aluminum alloy cylinder blocks of automobile engines are studied in this article in order to effectively improve the overall performance of the automobile.
With the improvement in China's economic development, the level of aluminum alloy die casting technology for automobile engines is also gradually improving. In order to meet people's demand for energy saving and emission reduction, the existing aluminum alloy cylinder block die casting technology for automobile engines has been innovated. Combine cast iron and aluminum alloy to manufacture automobile engine blocks. At present, the cylinder blocks of many automobile engines in China are made from sand cast iron. Although this material has very good heat resistance and relatively low costs, its shortcomings are also very obvious. The weight of cast iron cylinder blocks is very heavy, and the advantages of the aluminum alloy cylinder block are very obvious. It not only reduces the weight of the cylinder block, but also has the advantage of lower cost.
1. Advantages and disadvantages of the cylinder block die casting process
1.1 High efficiency
Die casting process is often used in automobile manufacturing. This process adopts rapid die casting forming process during die casting. This process can reduce the cost of machinery manufacturing, increase the productivity of machinery manufacturing and shorten manufacturing time of aluminum alloy cylinder blocks of automobile engines. When manufacturing automobile machinery, if traditional manufacturing methods are used, it will take a week to manufacture aluminum alloy cylinder blocks for automobile engines and about two weeks to machine the cylinder block.
1.2 The accuracy of cylinder block die casting is further improved.
1.3 The toughness and surface hardness of castings are good.
1.4 Reduce material costs. Generally, each set of machine can produce about 70,000 pieces per year.
1.5 Occupies less land area.
1.6 Simplified processes
Compared with the traditional cylinder block die casting time, the manufacturing process of the traditional die casting process is relatively more complicated. When performing the cylinder block die casting processing, a lot of manpower and material resources are required for the processing personnel. In comparison with the traditional die casting process, the advantages of the die casting process are very obvious. The new die casting process does not need to go through a very cumbersome processing process. During processing, there are fewer burrs and trimming. The processing personnel only need to take out the mold after it is processed. In addition, after the mold is completed, casting treatment must be carried out. The processing technology must be strictly inspected to ensure processing quality of the aluminum alloy cylinder block of the automobile engine.
1.7 Die casting also has certain disadvantages.
1.7.1 There are many die casting defects.
Compared with other automobile engine aluminum alloy processing technology, the die casting processing technology is relatively more complicated. When the die casting is performed, the personnel need to pour the metal into the cavity of the engine aluminum alloy cylinder block. Much gas porosity is prone to appear on surfaces of aluminum alloy cylinder blocks of automobile engines. These gas porosity will not only affect the appearance of the product, but also make quality of the product poor. During the product filling process, if there are oxidized impurities in the filling liquid and these impurities are not discharged in time during filling, a large number of impurities will be mixed inside the die casting, which will seriously reduce strength of die castings.
1.7.2 Die castings have high initial investment costs.
A certain amount of die casting needs to be ensured so that the investment cost won't be in deficit.
2. Cause analysis of leakages in the oil circuit of the engine cylinder block
When the aluminum alloy cylinder block of the automobile engine is die-casted, the oil circuit of the cylinder block often leaks. It is found that the main reason is the sealing between threaded holes of engines and oil circuit holes of cylinder blocks is not well after inspecting the engine block. Many holes on the outside of the cylinder block are found after inspecting the inside and outside of the cylinder block. After analyzing positions of leakages on the cylinder block, it can be found that the appearance of the hole is related to the position of the hole where the oil leaks. The thickness of the oil leakage position of the cylinder block is very different, which causes the generation of shrinkage porosity inside the die casting and the oil leakage problem of the cylinder block. Most of the holes in the cylinder block are shrink holes, which are not easy to be solved.
As an important part of a car, the engine can provide enough power for the car, which has a great impact on the environmental protection and safety of the car. In addition, compared with the traditional die casting process of aluminum alloy cylinder blocks, the improved cylinder block die casting process can effectively avoid a series of problems, for example oil leakage in automobile engines, and improve the reliability and safety of automobile operation. The improvement measures of die casting of aluminum alloy cylinder blocks of automobile engines are studied in this article in order to effectively improve the overall performance of the automobile.
With the improvement in China's economic development, the level of aluminum alloy die casting technology for automobile engines is also gradually improving. In order to meet people's demand for energy saving and emission reduction, the existing aluminum alloy cylinder block die casting technology for automobile engines has been innovated. Combine cast iron and aluminum alloy to manufacture automobile engine blocks. At present, the cylinder blocks of many automobile engines in China are made from sand cast iron. Although this material has very good heat resistance and relatively low costs, its shortcomings are also very obvious. The weight of cast iron cylinder blocks is very heavy, and the advantages of the aluminum alloy cylinder block are very obvious. It not only reduces the weight of the cylinder block, but also has the advantage of lower cost.
1. Advantages and disadvantages of the cylinder block die casting process
1.1 High efficiency
Die casting process is often used in automobile manufacturing. This process adopts rapid die casting forming process during die casting. This process can reduce the cost of machinery manufacturing, increase the productivity of machinery manufacturing and shorten manufacturing time of aluminum alloy cylinder blocks of automobile engines. When manufacturing automobile machinery, if traditional manufacturing methods are used, it will take a week to manufacture aluminum alloy cylinder blocks for automobile engines and about two weeks to machine the cylinder block.
1.2 The accuracy of cylinder block die casting is further improved.
1.3 The toughness and surface hardness of castings are good.
1.4 Reduce material costs. Generally, each set of machine can produce about 70,000 pieces per year.
1.5 Occupies less land area.
1.6 Simplified processes
Compared with the traditional cylinder block die casting time, the manufacturing process of the traditional die casting process is relatively more complicated. When performing the cylinder block die casting processing, a lot of manpower and material resources are required for the processing personnel. In comparison with the traditional die casting process, the advantages of the die casting process are very obvious. The new die casting process does not need to go through a very cumbersome processing process. During processing, there are fewer burrs and trimming. The processing personnel only need to take out the mold after it is processed. In addition, after the mold is completed, casting treatment must be carried out. The processing technology must be strictly inspected to ensure processing quality of the aluminum alloy cylinder block of the automobile engine.
1.7 Die casting also has certain disadvantages.
1.7.1 There are many die casting defects.
Compared with other automobile engine aluminum alloy processing technology, the die casting processing technology is relatively more complicated. When the die casting is performed, the personnel need to pour the metal into the cavity of the engine aluminum alloy cylinder block. Much gas porosity is prone to appear on surfaces of aluminum alloy cylinder blocks of automobile engines. These gas porosity will not only affect the appearance of the product, but also make quality of the product poor. During the product filling process, if there are oxidized impurities in the filling liquid and these impurities are not discharged in time during filling, a large number of impurities will be mixed inside the die casting, which will seriously reduce strength of die castings.
1.7.2 Die castings have high initial investment costs.
A certain amount of die casting needs to be ensured so that the investment cost won't be in deficit.
2. Cause analysis of leakages in the oil circuit of the engine cylinder block
When the aluminum alloy cylinder block of the automobile engine is die-casted, the oil circuit of the cylinder block often leaks. It is found that the main reason is the sealing between threaded holes of engines and oil circuit holes of cylinder blocks is not well after inspecting the engine block. Many holes on the outside of the cylinder block are found after inspecting the inside and outside of the cylinder block. After analyzing positions of leakages on the cylinder block, it can be found that the appearance of the hole is related to the position of the hole where the oil leaks. The thickness of the oil leakage position of the cylinder block is very different, which causes the generation of shrinkage porosity inside the die casting and the oil leakage problem of the cylinder block. Most of the holes in the cylinder block are shrink holes, which are not easy to be solved.
