This planetary gear frame was pro- duced using ADI.


图5 ADI行星齿轮架 。


年4500多吨，预计今年将达 7000~8000吨。


to develop an ADI crankshaft for turbocharging engines in the 1.8T and 2.0T Besturn. Performance and fatigue test- ing have been completed, and bench testing is ongoing. The program is expected to be the first formally manufac- tured set of ADI crankshafts. Jiangsu Wanli Machinery Co. Ltd. has been testing the use of ADI crankshafts for multi-cylinder diesel engines but hasn’t yet begun production. The first formal, mass-produced ADI component was the timing gear in high-power diesel engines. The timing gears in Cummins engines produced by Dongfeng Motor Corp., Hubei, China, and the crankshaft timing gears in 6DF1 diesel engines produced by FAW Wuxi Diesel Engine Works, Jiansu, China, have a safety factor of bending fatigue strength as high as 3.56. While ADI gears can safely substitute nitride steel


timing gears and partly carburized-quenching steel gears, they have not been widely used due to price. Iron and steel production has been growing rapidly in China, which has greatly reduced steel cost. In the 1990s, when Dongfeng Motor Corp. converted to ADI for gear production, the price of a Φ80 section of low alloyed steel was $1,264 per ton, while the price of high grade pig iron was $110 per ton. The manufacturing cost for a of six ADI gears was $20 and saved 17% compared with steel gears. At present, the price of steel has decreased to about $632 per ton, but the price of high grade pig iron has increased to $632 per ton. Recently, some companies have tried to reduce cost


by improving the quality of ductile iron castings and decreasing rejection rates, controlling heat treatment, and reducing machine tooling costs (like eliminating the expensive gear grinding process). Some companies have tested and manufactured ADI


spiral bevel gears, but their production level is small. SEW Co., Tianjin, China, which uses ADI gears


in a range of products, purchased the Finnish Kymi Kymmene Factory. Since it established its plant in Tianjin, SEW has been taking an active part in the development of the ADI industry in China. In 2009, its ADI production volume was 500-600 tons; it reached an estimated 1,000 tons in 2011. ■


ADI曲轴、齿轮


近年来，增压技术在汽油 发动机上也开始应用，一汽 集团铸造公司也进行了1.8T和


2.0T奔腾轿车增压发动机ADI曲轴的开发，性能试验和 疲劳试验均已完成，现正等待台架试验结果。它有望成 为我国首批正式批量生产的ADI曲轴。


江苏万力机械股份有限公司多年来也一直进行多缸柴 油机ADI曲轴试验工作，也取得较好效果，但也未用于 生产。


齿轮是ADI最早用于工业化生产的产品，美国、芬 兰、中国最早开发的都是ADI齿轮。ADI齿轮具有抗弯 曲疲劳和接触疲劳强度高、抗点蚀能力强、噪音小、重 量比同尺寸钢齿轮减轻10％、热处理变形小、加工性能 好、刀具寿命长和成本低等一系列优点。在我国汽车、 拖拉机行业中有较多的开发应用，最早用于轻型、中型 载重汽车的后桥伞齿轮的配件上，但批量均不大。批 量生产用于正式产品上为大功率柴油发动机上的正时齿 轮。东风汽车公司生产的康明斯发动机正时齿轮、一汽 集团解放汽车有限公司锡柴分司生产的6DF1柴油机曲 轴正时齿轮，齿轮弯曲疲劳强度安全系数可达3.56倍。 实践证明，用ADI齿轮代替氮化钢正时齿轮和部分渗 碳淬火钢齿轮在使用中是完全没有问题的。妨碍ADI正 时齿轮应用的主要原因是价格问题。由于我国钢铁工业 发展很快，大容量高炉+纯氧顶吹+连续轧制的钢材生 产工艺大大降低钢材的成本，20世纪90年代东风汽车 公司用ADI代替ANST1022渗碳钢时，Φ80大截面低合 金钢价格为8000元/吨，优质生铁价格为700元/吨，每 套（六个齿轮）ADI齿轮较钢齿轮制造费降低17%，约 124元；目前钢材价格降至4000元/吨左右，而优质铸 造生铁则升至4000元/吨，因此，如何降低ADI齿轮成 本便成为扩大ADI齿轮应用的关键之一。 近来一些单位试图通过提高球铁毛坯件质量降低废品 率，控制热处理质量，降低机加工成本（如是否可以减 去昂贵的磨齿工序）等措施来降低成本。 ADI后桥螺旋伞齿轮也有一些单位一直坚持进行试验 和生产，但未形成规模生产。 SEW公司收购了芬兰的Kymi Kymmene厂，在它的 产品中，一直坚持用ADI齿轮，图3、图4为其两件典型 产品。自在中国天津建厂后一直积极参加中国ADI行业 的各项活动，2009年ADI产量500~600吨，预计2011


年达1000多吨。 ■


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Spring 2012 FOUNDRY-PLANET.COM | MODERN CASTING | CHINA FOUNDRY ASSOCIATION | 35


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