product news/產品新聞
After addressing a few of the customer’s needs, Monarch In- dustries then simultaneously handled FEA and simulation. “For our FEA, everything came up the first go-around.
Tere were no issues,” said Mark Hildebrand, general man- ager, Monarch Industries. “In parallel with that, we ran it through Magma simulation, which only required a few itera- tions to make sure it was moldable and tooling was feasible.” Turnaround time for an initial design can be a matter
of days. When customers see a feasible design that reduces costs, they can’t help but be interested. “We took a quick look at it and told them our initial de-
sign would cost them X, and they said, ‘Whoa, we like that,’” Hildebrand said. “Now it’s a matter of fine-tuning.” Monarch Industries, by reducing the demands on the
customer, hopes to ease the conversion of various parts to castings. Educating the customer on casting-specific consid- erations, such as tolerances, can remove potential roadblocks in the later stages of collaboration. “Instead of waiting on the customer’s engineer, you can
present ideas,” Hildebrand said. “We take a lot of the work away from them. We want to remove the hang-up from the customer’s engineering department.” Te casting conversion featured a single core in green
sand. Te new design features windows that act as core prints. Legacy design elements like drilled holes and bosses were removed to simplify the casting’s appearance. With an annual production volume of 2,000 pieces, the D64-45-12 ductile iron casting measures 22 x 12 x 10 in. and weighs 55 lbs. (25 kg). Te customer reduced costs by 25%, improved strength, freed up plant capacity in both the welding and fabrication departments, improved alignment in the holes and, with tighter hole-to-hole tolerances, eliminated issues related to warpage and assembly. ■
的，没有任何问题，”Monarch工业公司总经理Mark Hildebrand说，“与此同时，我们通过了Magma模拟 实验，只是需要反复的实验来保证铸件是可以成形的， 模具是可用的。”
初步设计的周期可以在几天完成。当把降低成本的 可行设计方案展示给客户时，他们绝对会感兴趣。 “快速观察后，我们就把初步设计方案以及 花费告知客户，然后他们说，‘哇，我们喜欢这个设 计，’”Hildebrand说，“现在需要进行的是方案的 细化调整。” Monarch工业公司通过减少对客户的要求，希望将 各种部件改为铸件变得更加容易。公司对客户进行铸件 具体考虑因素的指导，如公差，可以消除合作后期的潜 在障碍。
“不需依赖客户的工程师，任何人都可以提出自己 的观点，”Hildebrand说：“我们承担了工程师的很 多工作，我们想为客户的工程部门去除障碍。” 改后的铸件特点是湿砂单一芯核。设计特点是把窗 户作为了型芯座。传统的设计元素，例如钻孔和圆形凸 饰都被去除以简化铸件的外观设计。D64-45-12型号的 球墨铸铁件的年产量为2000件，尺寸为22 x 12 x 10英 寸，重为25kg。新的设计使客户降低了25%的成本， 提高了铸件强度、释放了焊接和装配设备的生产能力， 优化了钻孔的排列、使孔与孔之间的容差更紧密，还排 除了与翘曲和组装有关的问题。 ■
Plunger Tip for Automotive Aluminum Structural Die Casting 压铸铝合金汽车结构件冲头
There is strong interest in replacing structural steel
with structural aluminum alloys, such as Silafont 36, to reduce automotive weight and fuel consumption. The Silafont 36 structural casting component usually is heavier, between 25 and 35kg, and poured between 680C and 700C. The larger thermal mass and higher pour temperature require a plunger tip with supreme thermal and dimensional stability. Castool Tool-
当前，业界对铝合金结构件替代钢结构件有浓厚的 兴趣，例如使用Silafont 36，可以减轻汽车的重量、 降低燃油消耗。通常Silafont 36材料的结构件较重， 为25-35kg，浇注温度为680℃-700℃。较大的热熔 和较高的浇注温度要求冲头具有良好的热稳定性和尺
A design plunger tip is illustrated with the correspond- ing equation used to calculate the temperature of the tip surface.
如图所示为用冲头表面 温度的计算方程式说明 的特殊设计的冲头。
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FOUNDRY-PLANET.COM | MODERN CASTING | CHINA FOUNDRY ASSOCIATION December 2014
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