Production technology of thin wall complex structure casting

With the development of automobile industry and the demand of energy saving and emission reduction, the lightweight of automobile parts is becoming more and more important. Taking FAW Casting Co., Ltd. as an example for FAW Volkswagen’s production of cast iron cylinder block, the wall thickness of 06A cylinder block produced in the early stage is 4.5mm ± 1.5mm, and that of EA111 cylinder block is 4mm ± 1mm. At present, the wall thickness of ea888evo 2 cylinder block produced in batch is 3.5mm ± 0.8mm, and the structure of the next generation ea888gen. 3 cylinder block is more complex, its wall thickness is only 3mm ± 0.5mm, which is the thinnest gray cast iron cylinder block at present. Although there are many problems in batch production, such as broken core, floating core and large fluctuation of wall thickness, by controlling the quality of sand core and molding sand, the horizontal horizontal horizontal pouring process widely used at present can meet the production requirements of ea888evo 2 cylinder block, but it can not meet the production requirements of ea888gen. 3 cylinder block, so it is necessary to adopt the integral core vertical pouring process.

According to the characteristics of 3 mm thin wall of cylinder block, the vertical casting technology of core assembly has put forward strict requirements for core making and core assembly. The core making center can realize the high intelligence and automation of the core making production. From the addition of original sand and resin, the whole process from sand mixing, core making, core repairing, assembly, coating and drying to molding and core setting can be highly automated, so that the core making quality, assembly quality, i.e. dimensional accuracy and coating drying quality can be guaranteed stably, thus avoiding the quality and dimensional risks caused by human factors, It can meet the needs of large scale cylinder system core production. It can effectively solve the problem of unstable and high scrap rate in mass production. At the same time, due to the improvement of the size accuracy of sand core, it also greatly reduces the cleaning workload and cost, and can effectively guarantee the requirement of 3 mm wall thickness.