product news/產品新聞
the walls were thick and difficult to produce. Te original die casting did not pass the 5-bar leak test without impregnation. Te housing was cast via SSR to decrease porosity, reduce
cycle times and lower draft angles on cores. In the trial, 100% of the castings passed the leak test without impregna- tion. Te castings used 0.2 degree core draft angles, eliminat- ing machining steps. Gate thickness was increased to 5 mm, requiring the use of a saw to remove the gate, runner and biscuit from the casting. Cycle time was reduced by 20%, mainly due to the reduction in cooling of the multi-slide die. Te casting is now in commercial production with the SSR process at an annual volume of 60,000 parts. Te second casting selected for testing, a steering rack, was another pressure-sensitive casting on which the custom- er required low porosity to minimize scrap after machining and avoid leaking. Te diecasting supplier producing the part had a minimal scrap rate; however, an increased reduction in porosity was required to lower the scrap rate further. Besides porosity reduction, the SSR process was expected to reduce cycle time, decrease lubrication usage and improve die life. According to the results of the trial, the cycle time was
reduced by 18 seconds and die lubrication usage was cut by 50%, primarily due to reduced spray time. X-ray images and visual inspection of sectional pieces showed a decrease in po- rosity. Te overall rejection rate of the casting was decreased
from 8% to less than 4%. ■ Visit
www.idragroup.com for more information.
压铸件没有通过压力为5巴的渗漏试验。 采用SSR浇注的壳降低了孔隙率，缩短了生产周期并 减小了拔模斜度。在测试中，全部的铸件在没有经过浸 渗的情况下，都通过了渗漏检测。铸件采用了0.2°的拔 模斜度，减少了机加工的环节。浇口的厚度增加了5毫 米，浇注系统需要被锯掉。生产周期减少了20%，这 主要是因为铸件冷却时间大幅减少。现在公司每年采用 SSR生产的铸件达到了60,000件。
第二个进行测试的铸件是转向架，也是对压力敏感的 铸件。客户要求铸件的孔隙率要低，以减少机加工量并 避免渗漏。压铸已经可以减少铸件的切削量；但顾客还 需要进一步降低孔隙率以减少切削量。而且SSR还可以 缩短生产周期，减少润滑油的使用，提高模具寿命。 试验结果显示，由于喷雾时间的减少，生产周期缩短 了18秒，模具润滑油的使用减少了50%。对于铸件试样 的目测和X射线检测都显示孔隙率降低。整体铸件的废 品率从8%降低到不超过4%。 ■ 获取更多信息，请登陆
www.idragroup.com。
This oil pump filter housing was produced in the SSR process to decrease porosity and reduce cycle times.
SSR的应用降低了过滤泵壳的 孔隙率，缩短了生产周期。
Fall 2011
FOUNDRY-PLANET.COM | MODERN CASTING | CHINA FOUNDRY ASSOCIATION | 69
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40 |
Page 41 |
Page 42 |
Page 43 |
Page 44 |
Page 45 |
Page 46 |
Page 47 |
Page 48 |
Page 49 |
Page 50 |
Page 51 |
Page 52 |
Page 53 |
Page 54 |
Page 55 |
Page 56 |
Page 57 |
Page 58 |
Page 59 |
Page 60 |
Page 61 |
Page 62 |
Page 63 |
Page 64 |
Page 65 |
Page 66 |
Page 67 |
Page 68 |
Page 69 |
Page 70 |
Page 71 |
Page 72 |
Page 73 |
Page 74 |
Page 75 |
Page 76 |
Page 77 |
Page 78 |
Page 79 |
Page 80 |
Page 81 |
Page 82 |
Page 83 |
Page 84 |
Page 85