ITALPRESSE TF無曲拐兩板機(jī)

InnovativeDevelopmentsandTechnologyImprovementsinHighPressureDieCasting高壓壓鑄的創(chuàng)新發(fā)展與技術(shù)進(jìn)步ChinaDieCastingDevelopmentForum亞太地區(qū)壓鑄工業(yè)發(fā)展論壇(GuangdongModernInternationalExhibitionCenterHoujie,Dongguan)September16th-17th,2013Speaker:Mr.MaurizioCordova演講人：意特全球銷售總監(jiān)MaurizioCordova先生FullVersionAvailableonRequest:maurizio.cordova@italpresse.it

Summary概述:Technicalcomparebetween2and3platendiecastingmachine

兩板機(jī)與三板機(jī)的技術(shù)比較

-LatestadvancementswithCeramicCoresforspecialshapecastings

帶陶瓷芯特殊形狀鑄件的最新發(fā)展Casestudiesandapplications實(shí)例分析與應(yīng)用:

Structuralandsafetyautomotiveparts

汽車結(jié)構(gòu)及安全部件

-FullautomationconceptforEngineBlocks

發(fā)動機(jī)缸體全自動化

-Transmissioncasesandcomplexgeometrycastings

變速箱及復(fù)雜鑄件ConventionalThreePlatenMachine傳統(tǒng)三板機(jī)曲拐系統(tǒng)

REACTIONPLATEN后模座MOVINGPLATEN動模板FIXEDPLATEN定模板TOGGLE曲拐TOGGLESYSTEMCLAMPINGCYLINDER合模油缸TF=“ToggleFree”Machine無曲拐壓鑄機(jī)OverallView透視圖CROSSMEMBER橫梁MOVINGPLATEN動模板FIXEDPLATEN定模板BLOCKCYLINDERS鎖緊油缸HALF-NUTS半圓螺母TIEBAR大杠HALF-NUTS半圓螺母SHIFTPISTONS推進(jìn)活塞TF=“ToggleFree”Machine無曲拐壓鑄機(jī)MachineClosing機(jī)器合模3.Half-nutsclosing半圓螺母閉合2.Movingplatenshift動模板移動1.FromDCM“opened”…開模4.Blockcylinderspressurization鎖緊油缸施壓

TF=“ToggleFree”Machine無曲拐壓鑄機(jī)MachineOpening機(jī)器開模2.Half-nutsre-positioning半圓螺母重新定位3.Half-nutsopening半圓螺母打開4.Movingplatenshift動模板移動1.Blockcylindersdepressurization

鎖緊油缸卸壓TFvsTogglecomparison有無曲拐的對比Systemrigiditycalculations整體剛度計算LALAEβE

=ELASTICMODULUS彈性系數(shù)β

=COMPRESSIBILITYMODULUS壓縮系數(shù)TFMACHINE無曲拐TOGGLEMACHINE有曲拐A

=UTILESECTION有用截面L

=COMPONENTLENGTH組件長度TFvsTogglecomparison有無曲拐的對比Systemrigiditycalculations整體剛度計算E

=ELASTICMODULUS彈性系數(shù)β

=COMPRESSIBILITYMODULUS壓縮系數(shù)TFMACHINE無曲拐TOGGLEMACHINE有曲拐THERIGIDITYREFERREDTOAPARTICULARSYSTEMONLYDEPENDSONTHESYSTEMITSELFANDNOTONEXTERNALCONDITIONS系統(tǒng)剛性取決于系統(tǒng)本身，而不受外部條件影響A

=UTILESECTION有用截面L

=COMPONENTLENGTH組件長度TFvsTogglecomparison有無曲拐的比較Systemrigidityresults系統(tǒng)剛性結(jié)果機(jī)器剛性機(jī)器合模力

TFvsTogglecomparison有無曲拐的比較Diecompressioncalculations模具壓力計算Referencedie:模具參數(shù)B

=TIEBARSCLEARANCE大杠間隙L

=AVERAGEDIEHEIGHT平均模具高度A

=UTILESECTION有用截面E

=ELASTICMODULUS彈性系數(shù)BBLABoundaryconditions:分界條件Fext

=NOMINALMACHINECLAMPINGFORCE正常機(jī)器合模力TFvsTogglecomparison有無曲拐的比較Diecompressionresults模具受力分析伸長率（mm）TFvsTogglecomparison有無曲拐的比較Diecompressionresults模具受力分析模具受力機(jī)器合模力TFvsTogglecomparison有無曲拐的比較Operativeconditions設(shè)備運(yùn)轉(zhuǎn)情況OVERALLDIMENSIONS設(shè)備總體尺寸機(jī)器長度機(jī)器鎖模力TFvsTogglecomparison有無曲拐的比較Operativeconditions設(shè)備運(yùn)轉(zhuǎn)情況Betteradaptationcapacitytothediedeformationswhilediecasting在壓鑄的應(yīng)用上，對于模具的形變具有更好的適應(yīng)性Moreuniformstressdistributiononmechanicalcomponents(mainlydieandplatens)更均勻的受力分配，包括模具和模板Bettermachineadjustmenttothediecentreofpressure可以更好的調(diào)節(jié)模具的中心受力Remarkablewearreduction明顯減少設(shè)備磨損情況Machinelubricationsaving減少機(jī)器潤滑Simplerandfasterdiesettingoperations更快更簡單實(shí)現(xiàn)模具設(shè)定操作CaseStudiesAutomotive汽車工業(yè)實(shí)際案例分析Since1969ITALPRESSE,hasdevelopedanddeliveredhundredsofauto-cells,mainlywiththeautomotiveO.E.M.andTier1.從1969年開始，ITALPRESSE已經(jīng)為汽車工業(yè)OEM和整車廠商制造生產(chǎn)了數(shù)百套全自動壓鑄生產(chǎn)單元。Inthenextpagessomecase-historiesshowingcompletecellswhereItalpresseas“onesolesupplier”wasinchargefortheentireturnkeyproject.我們將在以下幾個頁面為您介紹ITALPRSSE的實(shí)際交鑰匙工程案例，并向您展示ITALPRESSE“做一家獨(dú)一無二的壓鑄機(jī)生產(chǎn)商”的理念。Industriallight照明工業(yè)TFMachineTF機(jī)器噸位1000tonsCastingweight鑄件重量8kilosDiecaster壓鑄廠商Customer最終客戶800mm400mmCaseStudy–TF-1000案例分析——TF1000CaseStudy:TF-1350案例分析：TF1350Client:BDW客戶：BDWCasting:“Topf1”forHPGetriebe鑄件：變速箱外殼“Topf1”，HPGeriebe公司Alloy:Aluminum鑄件材質(zhì)：鋁

StructuralCasting結(jié)構(gòu)鑄件

Part:RoofFrame(MercedesSL/SLK)部件：車頂骨架（MercedesSL/SLK）StructuralCastings結(jié)構(gòu)鑄件

ItalpresseCellforDaimlerItalprese壓鑄單元，客戶：Daimler

InProductionwithTF2150-3000–4000,TF2150-3000-4000壓鑄單元Casting:RoofFrame鑄件：車頂骨架Alloy:MagnesiumandAluminum材質(zhì)：鎂鋁Turn-keySolution,Process,AutomationOptimization全單元交鑰匙工程，工藝流程最優(yōu)自動化設(shè)計StructuralCasting結(jié)構(gòu)鑄件

ItalpresseCellforDoktasItalprese壓鑄單元，客戶：DoktasMachine:IP-3000SC機(jī)器型號：IP3000SCCasting:CrossMember-subframe鑄件：汽車副車架Alloy:Silafont36材質(zhì)：硅鋁合金36

TheLay-OutConceptbasedon2500tonDCM

2500噸壓鑄單元布局圖CaseStory-EngineBlocks案例：缸體壓鑄Client:KavianBaris客戶：KavianBarisMachine:IP-2500SC機(jī)器型號：IP2500SCCasting:L4EngineBlock鑄件：L4缸體Alloy:Aluminum材質(zhì)：鋁Turn-keySolution,Process,AutomationOptimization交鑰匙工程，最優(yōu)工藝設(shè)計

CaseStory-EngineBlocks案例-缸體壓鑄Client:NemakChina,India,Poland,Brasil.客戶：Nemak中國、印度、波蘭、巴西Machine:IP-2500SC機(jī)器型號：IP2500SCCasting:L4EngineBlock產(chǎn)品：L4缸體Alloy:Aluminum材質(zhì)：鋁Turn-keySolution,ProcessandAutomationOptimization交鑰匙工程，最優(yōu)工藝設(shè)計

CaseStory-EngineBlocks案例-缸體壓鑄Clients:KiaMotors,Hyundai,MartinreaMexico客戶：起亞、現(xiàn)代、Martinrea墨西哥Casting:V6EngineBlock產(chǎn)品：V6缸體Alloy:Aluminum材質(zhì)：鋁Turn-keySolution,ProcessandAutomationOptimization交鑰匙工程，最優(yōu)工藝設(shè)計

CaseStory–EgineBlocks案例-缸體壓鑄

(MartinreaMexico,BrazilandGermany客戶：Marinrea墨西哥，巴西和德國）Client:Martinrea

Mexico,BrazilandGermany客戶：Marinrea

墨西哥，巴西和德國Machine:IP3000-IP3500-TF4000機(jī)器型號：IP3000-IP3500-TF4000Casting:V6Engineblock產(chǎn)品：V6缸體Alloy:Aluminum材質(zhì)：鋁

CompleteCellSolutionsforLargeAutomotiveParts

(TransmissionCase,OilSump,Crankcase,ClutchHousing).

整套單元解決方案-大型汽車部件（變速箱，油底殼，曲軸箱，離合器箱）Clients客戶:-MartinreaBrazilMartinrea巴西-FPAlu(Eurocast)-ShaanxiFastAutoDrive陜西法士特-GeneralMotorsKorea通用韓國-Co.Stamp科斯坦普

CaseStory案例

TransmissionCase變速箱Client:GM客戶：GMMachineType:IP2500機(jī)器型號：IP2500SCCastingType:AutomaticTransmissionCase產(chǎn)品：自動變速箱Alloy:Aluminum材質(zhì)：鋁

CeramicCoresforSpecialShapeCastings特殊形狀鑄件使用陶瓷鑲件Challenge挑戰(zhàn):HighPressureDiecastingusingCeramicCoresinStructuralandHighIntegrityParts在結(jié)構(gòu)件和完整性要求更高的鑄件壓鑄上使用陶瓷鑲件Study,developmentandindustrializationofaninnovativehighpressurediecastingprocessusingceramiclostcorestoproducestructuralandhighintegritycomplexshapeparts在結(jié)構(gòu)件和復(fù)雜形狀完整性鑄件的壓鑄上，一個革新是對陶瓷鑲件使用的研究、發(fā)展和工業(yè)化ProjectTeam項目團(tuán)隊成員:Italpresse,UniversityofBrescia,Lomopress,Costamp,Piq2Italpresse，布雷西亞大學(xué)，Lomopress，Costamp,Piq2Benefits優(yōu)點(diǎn):FinalPartCostReduction:cheapertechnology,noassembly.產(chǎn)品最終成本的減少：更便宜的工藝，無需組裝FreeCoreShapesDesign:hollowandcomplexshapesarepossible,evenwithundercutandsecondarycavities.自由鑲件設(shè)計：使空心和復(fù)雜的形狀成為可能，甚至可以使用切口和二級縮孔ExcellentHighTemperatureMechanicalProperties:nodeformationduringcastingandsolidificationevenwithlowthicknesscores.優(yōu)秀的高溫機(jī)械性能：在鑄造和凝固過程當(dāng)中不存在變形，甚至非常薄的鑲件也具有這個性能CeramicCoresforSpecialShapeCastings特殊形狀鑄件使用陶瓷鑲件Benefits優(yōu)點(diǎn):NoGasProductionDuringCasting:ceramicdoesnotreacttoformgaseswhenheatedbymoltenaluminum在鑄造過程當(dāng)中沒有氣體產(chǎn)生：陶瓷在加熱過程當(dāng)中不會產(chǎn)生氣體NoNegativeEffectsonAlloyCorrosionResistance:ceramicistheinert?parexcellence?對金屬耐蝕性不會產(chǎn)生負(fù)面影響：陶瓷是惰性的Closedshapecasting:higherstiffnessofparts封閉形狀鑄造：可以使鑄件的剛度更高CeramicCoresforSpecialShapeCastings特殊形狀鑄件使用陶瓷鑲件Benefits優(yōu)點(diǎn):LowCost:bothforrawmaterialandprocessingequipment.更低成本：無論是原料還是工藝設(shè)備EnvironmentFriendly:removedcoresareaninertandcanbereusedintheprocessitselforinthecivilbuildingfield.更好的環(huán)保性：惰性鑲件具有可移除性，并且可以循壞使用VariousDecoringTechniques:highpressurewaterjet,sandblastingorotherinnovativeprocessesaccordingtocoreshapeandcomplexity.更多樣的除芯技術(shù)：可以使用高壓水，振砂技術(shù)或者其他根據(jù)鑲件形狀和其復(fù)雜程度制定的去除工藝CeramicCoresforSpecialShapeCastings特殊形狀鑄件使用陶瓷鑄件TheProject項目情況:LOMOPRESSonIPMidSizeMachine:Development,engineeringandproductionofacomplexshapewaterintakemanifoldforautomotiveapplications.LOMOPRESS使用意特中型設(shè)備設(shè)計生產(chǎn)復(fù)雜形狀鑄件，并對其自動化應(yīng)用進(jìn)行研究工作COSTAMPonIPLargeSizeMachine:Development,reengineeringandproductionofanautomotivestructuralpart.COSTAMP使用意特大型設(shè)備設(shè)計生產(chǎn)汽車結(jié)構(gòu)件CeramicCoresforSpecialShapeCastings特殊形狀鑄件使用陶瓷鑲件Highmechanicalproperties:機(jī)械性能很高Flexuralstrength(Rf)彎曲強(qiáng)度（Rf）Pressureresistance(P)耐壓性Stiffness(YoungModulusE)剛度-Rf:4–60MPa(ondemand)-P>1500bar;-E>6GPaSimulation:vIngate=55m/s;E=4GPa(Stiffnessofshellsandcore)CeramicCoresProperties陶瓷鑲件性能MaProfSAS:Projectpartner,carriesthepatentoftheceramiccores(PCT/IB2010/002918)MaProfSAS：項目合作伙伴，持有陶瓷鑲件的專利（PCT/IB2010/002918)CeramicCoresforSpecialShapeCastings特殊形狀鑄件使用陶瓷鑲件

DifferentTestsinProduction在生產(chǎn)中進(jìn)行測試

DieCastingDie壓鑄模具Casting鑄件Finishedparts最終產(chǎn)品Protot