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11
2022
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Development of Automotive Castings
The application of non-ferrous alloy castings such as aluminum and magnesium, the development of large and complex structural integrated castings, and the widespread application of precision casting technology are the main ways to achieve lightweight automotive castings. Widespread application and other means to achieve the research and development and production of automotive castings to meet the needs of the modern automotive industry.
The application of non-ferrous alloy castings such as aluminum and magnesium, the development of large and complex structural integrated castings, and the widespread application of precision casting technology are the main ways to achieve lightweight automotive castings. The research and development and production of automotive castings are realized through widespread application and other means to meet the needs of the modern automotive industry.
Casting is one of the oldest metal forming methods. Approximately 15% to 20% of automotive parts are castings produced by different casting methods. These castings are mainly key components of the power system and important structural components. At present, the automotive casting production technology in developed countries in Europe and the United States is advanced, the product quality is good, the production efficiency is high, and the environmental pollution is small. Casting raw and auxiliary materials are serialized and standardized, and the entire production process is mechanized, automated, and intelligent. These countries generally use digital technology to improve the design level of casting technology. The scrap rate of castings is about 2% to 5%, and a multinational service system and network technology support have been established. In contrast, although my country's automotive casting output is relatively large, most of them are black castings with low added value and technical content, and the structure is relatively simple, which is far from the international level. This article mainly discusses the development direction of automotive castings and automotive technology from the perspective of the development needs of automotive energy conservation and environmental protection.
1 Development direction of automotive castings
1.1 Integrated design of automotive castings
With the increasing requirements for energy saving, environmental protection and reduction of production costs in automobiles, the advantages of casting and forming are fully utilized. The original stamping, welding, forging, and casting parts are integrated into one-piece forming parts through reasonable design and structural optimization. Casting molding can reduce the weight of parts and reduce unnecessary processing procedures, thereby achieving lightweight and high performance of parts. The integrated bridge shell is used to replace the welded bridge shell and the new product casting bridge shell of the semi-axle shell to realize the integrated casting of the casting and give full play to the advantages of casting. At present, the main form of the ordinary casting integral bridge shell is to use a seamless steel pipe as a half Axle sleeves press into both ends of the bridge shell and are fixed with pins to form a bridge shell assembly. In order to further improve the strength and rigidity of the bridge shell and simplify the process, FAW Group developed an integrated bridge shell that directly casts the bridge shell (the parts on both sides of the bridge shell in Figure 1) on the bridge shell. . The processing difficulty is greatly reduced, the cost is greatly reduced, the bridge shell structure tends to be simple, the bridge shell has good rigidity, can be made into a complex and ideal shape, the wall thickness can be changed, an ideal stress distribution can be obtained, the strength and rigidity are high, and the work is reliable. As the semi-axle sleeve is integrated, the size of the casting increases significantly. The length of the casting is 2 258 mm, and the weight of a single piece exceeds 200 kg. In response to the characteristics of this integrated casting, the company has established a dedicated production line to ensure production.
The development trend of integrated automotive castings is more obvious in the development of non-ferrous alloy castings. In order to make full use of the advantages of the casting process to realize the production of castings with complex structures, integrated design high-pressure castings such as door inner panels, seat frames, instrument panel frames, front-end frames, and firewalls have emerged, which are much larger than the high-pressure castings currently produced. For castings, production requires 4 000~5 000 t or even larger tonnage die-casting machines.
1.2 Lightweight automotive castings
On the premise of ensuring the strength and safety performance of the car, reduce the curb weight of the car as much as possible to achieve lightweight, thereby improving the power performance of the car, reducing fuel consumption, and reducing exhaust pollution. For every 100 kg reduction in the curb weight of the vehicle, fuel consumption per 100 kilometers can be reduced by 0.3~0.6 liters, and a 10% reduction in vehicle weight can improve fuel efficiency by 6%~8% . With the need for environmental protection and energy saving, the lightweight of automobiles
Automobile casting
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