Innovative Developments and Technology Improvements in High Pressure Die Casting 高压压铸的创新发展与技术进步

1. Innovative Developments and Technology Improvements in High Pressure Die Casting 高压压铸的创新发展与技术进步 China Die Casting Development Forum 亚太地区压铸工业发展论坛 (Guangdong Modern International Exhibition Center Houjie, Dongguan) September 16th-17th, 2013 Speaker: Mr. Maurizio Cordova 演讲人：意特全球销售总监Maurizio Cordova先生 Full Version Available on Request: maurizio.cordova@italpresse.it

2. Summary概述: • Technical compare between 2 and 3 platen die casting machine • 两板机与三板机的技术比较 Case studies and applications实例分析与应用: • Structural and safety automotive parts • 汽车结构及安全部件 - Full automation concept for Engine Blocks 发动机缸体全自动化 - Transmission cases and complex geometry castings 变速箱及复杂铸件 - Latest advancements with Ceramic Cores for special shape castings 带陶瓷芯特殊形状铸件的最新发展

3. Conventional Three Platen Machine传统三板机 曲拐系统 TOGGLE SYSTEM TOGGLE曲拐 CLAMPING CYLINDER 合模油缸 REACTION PLATEN 后模座 FIXED PLATEN 定模板 MOVING PLATEN 动模板

4. TF = “Toggle Free” Machine 无曲拐压铸机 Overall View 透视图 HALF-NUTS半圆螺母 SHIFT PISTONS 推进活塞 BLOCK CYLINDERS 锁紧油缸 TIE BAR 大杠 HALF-NUTS 半圆螺母 FIXED PLATEN 定模板 MOVING PLATEN 动模板 CROSS MEMBER 横梁

5. TF = “Toggle Free” Machine 无曲拐压铸机 Machine Closing 机器合模 2. Moving platen shift 动模板移动 1. From DCM “opened”… 开模 3. Half-nuts closing 半圆螺母闭合 4. Block cylinders pressurization 锁紧油缸施压

6. TF = “Toggle Free” Machine 无曲拐压铸机 Machine Opening 机器开模 2. Half-nuts re-positioning 半圆螺母重新定位 1. Block cylinders depressurization 锁紧油缸卸压 4. Moving platen shift 动模板移动 3. Half-nuts opening 半圆螺母打开

7. TF vs Toggle comparison 有无曲拐的对比 System rigidity calculations 整体刚度计算 L L E= ELASTIC MODULUS弹性系数 β= COMPRESSIBILITY MODULUS压缩系数 β E A= UTILE SECTION有用截面 L= COMPONENT LENGTH组件长度 A A TOGGLE MACHINE有曲拐 TF MACHINE无曲拐

8. TF vs Toggle comparison有无曲拐的对比 System rigidity calculations整体刚度计算 E= ELASTIC MODULUS弹性系数 THE RIGIDITY REFERRED TO A PARTICULAR SYSTEM ONLY DEPENDS ON THE SYSTEM ITSELF AND NOT ON EXTERNAL CONDITIONS 系统刚性取决于系统本身，而不受外部条件影响 β= COMPRESSIBILITY MODULUS压缩系数 A= UTILE SECTION有用截面 L= COMPONENT LENGTH组件长度 TOGGLE MACHINE有曲拐 TF MACHINE无曲拐

9. TF vs Toggle comparison有无曲拐的比较 System rigidity results系统刚性结果 机器刚性 机器合模力

10. TF vs Toggle comparison有无曲拐的比较 Die compression calculations模具压力计算 B L Reference die: 模具参数 B= TIE BARS CLEARANCE大杠间隙 L= AVERAGE DIE HEIGHT平均模具高度 A= UTILE SECTION有用截面 E= ELASTIC MODULUS弹性系数 B A Boundary conditions: 分界条件 Fext= NOMINAL MACHINE CLAMPING FORCE正常机器合模力

11. TF vs Toggle comparison有无曲拐的比较 Die compression results模具受力分析 伸长率（mm）

12. TF vs Toggle comparison有无曲拐的比较 Die compression results模具受力分析 模具受力 机器合模力

13. TF vs Toggle comparison有无曲拐的比较 Operative conditions 设备运转情况 设备总体尺寸 OVERALL DIMENSIONS 机器长度 机器锁模力

14. TF vs Toggle comparison有无曲拐的比较 Operative conditions设备运转情况 • Better adaptation capacity to the die deformations while diecasting在压铸的应用上，对于模具的形变具有更好的适应性 • More uniform stress distribution on mechanical components (mainly die and platens)更均匀的受力分配，包括模具和模板 • Better machine adjustment to the die centre of pressure可以更好的调节模具的中心受力 • Remarkable wear reduction 明显减少设备磨损情况 • Machine lubrication saving 减少机器润滑 • Simpler and faster die setting operations更快更简单实现模具设定操作

15. Case Studies Automotive汽车工业实际案例分析 Since 1969 ITALPRESSE, has developed and delivered hundreds of auto-cells, mainly with the automotive O.E.M. and Tier1. 从1969年开始，ITALPRESSE 已经为汽车工业OEM和整车厂商制造生产了数百套全自动压铸生产单元。 In the next pages some case-histories showing complete cells where Italpresse as “one sole supplier” was in charge for the entire turn key project. 我们将在以下几个页面为您介绍ITALPRSSE的实际交钥匙工程案例，并向您展示ITALPRESSE “做一家独一无二的压铸机生产商”的理念。

16. Case Study – TF-1000案例分析——TF1000 Industrial light照明工业 Diecaster压铸厂商 Customer最终客户 800 mm TF MachineTF机器吨位 1000 tons Casting weight铸件重量 8 kilos 400 mm

17. Case Study: TF-1350案例分析：TF1350 • Client: BDW 客户：BDW • Casting: “Topf 1” for HP Getriebe铸件：变速箱外壳 “Topf1” ，HP Geriebe 公司 • Alloy: Aluminum 铸件材质：铝

18. Structural Casting结构铸件Part: Roof Frame (Mercedes SL/SLK)部件：车顶骨架（ Mercedes SL/SLK）

19. Structural Castings 结构铸件Italpresse Cell for Daimler Italprese压铸单元，客户：Daimler • In Production with TF 2150 - 3000 – 4000, • TF2150-3000-4000压铸单元 • Casting: Roof Frame • 铸件：车顶骨架 • Alloy: Magnesium and Aluminum • 材质：镁铝 • Turn-key Solution, Process, Automation Optimization • 全单元交钥匙工程，工艺流程最优自动化设计

20. Structural Casting 结构铸件Italpresse Cell for Doktas Italprese 压铸单元，客户：Doktas Machine: IP-3000SC 机器型号：IP3000SC Casting: Cross Member-sub frame 铸件：汽车副车架 Alloy: Silafont 36 材质：硅铝合金36

21. The Lay-Out Concept based on 2500 ton DCM2500吨压铸单元布局图

22. Case Story - Engine Blocks 案例：缸体压铸 Client: Kavian Baris客户：Kavian Baris Machine: IP-2500SC机器型号：IP2500SC Casting: L4 Engine Block铸件：L4缸体 Alloy: Aluminum材质：铝 Turn-key Solution, Process, Automation Optimization交钥匙工程，最优工艺设计

23. Case Story - Engine Blocks案例-缸体压铸 Client: Nemak China, India, Poland, Brasil.客户：Nemak中国、印度、波兰、巴西 Machine: IP-2500SC机器型号：IP2500SC Casting: L4 Engine Block产品：L4缸体 Alloy: Aluminum材质：铝 Turn-key Solution, Process and Automation Optimization交钥匙工程，最优工艺设计

24. Case Story - Engine Blocks案例-缸体压铸 Clients: Kia Motors, Hyundai, Martinrea Mexico客户：起亚、现代、Martinrea 墨西哥 Casting: V6 Engine Block产品：V6缸体 Alloy: Aluminum材质：铝 Turn-key Solution, Process and Automation Optimization交钥匙工程，最优工艺设计

25. Case Story – Egine Blocks 案例-缸体压铸(Martinrea Mexico, Brazil and Germany 客户：Marinrea 墨西哥，巴西和德国） Client: Martinrea Mexico, Brazil and Germany客户：Marinrea 墨西哥，巴西和德国 Machine: IP 3000 - IP 3500 - TF 4000 机器型号：IP3000-IP3500-TF4000 • Casting: V6 Engine block 产品：V6缸体 • Alloy: Aluminum材质：铝

26. Complete Cell Solutions for Large Automotive Parts(Transmission Case, Oil Sump, Crankcase, Clutch Housing).整套单元解决方案-大型汽车部件 （变速箱，油底壳，曲轴箱，离合器箱） Clients客户: - Martinrea Brazil Martinrea 巴西 - FP Alu (Eurocast) - Shaanxi Fast Auto Drive 陕西法士特 - General Motors Korea 通用韩国 - Co.Stamp 科斯坦普

27. Case Story案例Transmission Case变速箱 Client: GM 客户：GM Machine Type: IP 2500 机器型号：IP2500SC Casting Type: Automatic Transmission Case 产品：自动变速箱 Alloy: Aluminum材质：铝

28. Ceramic Cores for Special Shape Castings 特殊形状铸件使用陶瓷镶件 Challenge挑战: High Pressure Diecasting using Ceramic Cores in Structural and High Integrity Parts 在结构件和完整性要求更高的铸件压铸上使用陶瓷镶件 Study, development and industrialization of an innovative high pressure diecasting process using ceramic lost cores to produce structural and high integrity complex shape parts 在结构件和复杂形状完整性铸件的压铸上，一个革新是对陶瓷镶件使用的研究、发展和工业化 Project Team项目团队成员: Italpresse, University of Brescia, Lomopress, Costamp, Piq2 Italpresse，布雷西亚大学，Lomopress，Costamp,Piq2

29. Ceramic Cores for Special Shape Castings 特殊形状铸件使用陶瓷镶件 • Benefits优点: • Final Part Cost Reduction: cheaper technology, no assembly. • 产品最终成本的减少：更便宜的工艺，无需组装 • Free Core Shapes Design: hollow and complex shapes are possible, even with undercut and secondary cavities. • 自由镶件设计：使空心和复杂的形状成为可能，甚至可以使用切口和二级缩孔 • Excellent High Temperature Mechanical Properties: no deformation during casting and solidification even with low thickness cores. • 优秀的高温机械性能：在铸造和凝固过程当中不存在变形，甚至非常薄的镶件也具有这个性能

30. Ceramic Cores for Special Shape Castings 特殊形状铸件使用陶瓷镶件 • Benefits优点: • No Gas Production During Casting: ceramic does not react to form gases when heated by molten aluminum • 在铸造过程当中没有气体产生：陶瓷在加热过程当中不会产生气体 • No Negative Effects on Alloy Corrosion Resistance: ceramic is the inert «par excellence» • 对金属耐蚀性不会产生负面影响：陶瓷是惰性的 • Closed shape casting: higher stiffness of parts • 封闭形状铸造：可以使铸件的刚度更高

31. Ceramic Cores for Special Shape Castings 特殊形状铸件使用陶瓷铸件 • Benefits优点: • Low Cost: both for raw material and processing equipment. • 更低成本：无论是原料还是工艺设备 • Environment Friendly: removed cores are an inert and can be reused in the process itself or in the civil building field . • 更好的环保性：惰性镶件具有可移除性，并且可以循坏使用 • Various Decoring Techniques: high pressure waterjet, sandblasting or other innovative processes according to core shape and complexity. • 更多样的除芯技术：可以使用高压水，振砂技术或者其他根据镶件形状和其复杂程度制定的去除工艺

32. Ceramic Cores for Special Shape Castings 特殊形状铸件使用陶瓷镶件 • The Project项目情况: • LOMOPRESS on IP Mid Size Machine: Development, engineering and production of a complex shape water intake manifold for automotive applications. • LOMOPRESS 使用意特中型设备设计生产复杂形状铸件，并对其自动化应用进行研究工作 • COSTAMP on IP Large Size Machine: Development, reengineering and production of an automotive structural part. • COSTAMP 使用意特大型设备设计生产汽车结构件

33. High mechanical properties: 机械性能很高 Flexural strength (R f ) 弯曲强度（Rf） Pressure resistance (P) 耐压性 Stiffness (Young Modulus E) 刚度 - Rf : 4 – 60 MPa (on demand) - P > 1500 bar; - E > 6 GPa Ceramic Cores for Special Shape Castings 特殊形状铸件使用陶瓷镶件 • Ceramic Cores Properties陶瓷镶件性能 MaProf SAS: Project partner, carries the patent of the ceramic cores (PCT / IB2010 / 002918) MaProf SAS：项目合作伙伴，持有陶瓷镶件的专利（PCT/IB2010/002918) Simulation: vIngate= 55 m/s; E = 4 GPa (Stiffness of shell sand core)

34. Different Tests in Production在生产中进行测试 Casting铸件 Finished parts最终产品 Die Casting Die 压铸模具

35. Prototyping: One-Cylinder Engine Block 原型测试：单缸发动机缸体

36. Ceramic Cores for Special Shape Castings 特殊铸件使用陶瓷镶件 • The Project项目情况: • From ITALPRESSE: Diecasting Process, Automation Integration and Decoring Phase Development, in order to bring the Technology into an Efficient Production. • ITALPRESSE:为使这项技术尽早进入有效生产阶段，负责压铸工艺设计，自动化集成以及除芯工艺研究

37. Conclusions结论 • The “TF” Innovative Toggle Free Machine is the Answer to Improve the Diecasting Process and satisfy the latest • TF革新型无曲拐压铸机将是最新压铸工艺的发展方向 • Demands for Structural Parts and Ceramic Cores Diecasting. • 结构件的需求将促使陶瓷镶件的研究进入新的阶段 • The “TF” Solutions grant a Reduction of Mechanical Components, Better Balance and Less Maintenance. • 无曲拐压铸机可以极大减少机械部件，具备更好的平衡性能和更少的维修保养 • Elevated Automation and Advanced Electronic Solutions for a User-Friendly Operation. • 更高的自动化要求以及更友好的电气人机界面 • Significant Experience, Case Histories proving Reliable Equipment, Constant Casting Quality and Equipment Efficiency 通过以往的经验，案例证明了设备的可靠性，更高的铸件质量，以及设备的高效

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