ITALPRESSE TF無曲拐兩板機

InnovativeDevelopmentsandTechnologyImprovementsinHighPressureDieCasting高壓壓鑄的創(chuàng)新發(fā)展與技術進步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

兩板機與三板機的技術比較

-LatestadvancementswithCeramicCoresforspecialshapecastings

帶陶瓷芯特殊形狀鑄件的最新發(fā)展Casestudiesandapplications實例分析與應用:

Structuralandsafetyautomotiveparts

汽車結構及安全部件

-FullautomationconceptforEngineBlocks

發(fā)動機缸體全自動化

-Transmissioncasesandcomplexgeometrycastings

變速箱及復雜鑄件ConventionalThreePlatenMachine傳統三板機曲拐系統

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推進活塞TF=“ToggleFree”Machine無曲拐壓鑄機MachineClosing機器合模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MachineOpening機器開模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β

=COMPRESSIBILITYMODULUS壓縮系數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β

=COMPRESSIBILITYMODULUS壓縮系數TFMACHINE無曲拐TOGGLEMACHINE有曲拐THERIGIDITYREFERREDTOAPARTICULARSYSTEMONLYDEPENDSONTHESYSTEMITSELFANDNOTONEXTERNALCONDITIONS系統剛性取決于系統本身，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系統剛性結果機器剛性機器合模力

TFvsTogglecomparison有無曲拐的比較Diecompressioncalculations模具壓力計算Referencedie:模具參數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BBLABoundaryconditions:分界條件Fext

=NOMINALMACHINECLAMPINGFORCE正常機器合模力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器合模力TFvsTogglecomparison有無曲拐的比較Operativeconditions設備運轉情況OVERALLDIMENSIONS設備總體尺寸機器長度機器鎖模力TFvsTogglecomparison有無曲拐的比較Operativeconditions設備運轉情況Betteradaptationcapacitytothediedeformationswhilediecasting在壓鑄的應用上，對于模具的形變具有更好的適應性Moreuniformstressdistributiononmechanicalcomponents(mainlydieandplatens)更均勻的受力分配，包括模具和模板Bettermachineadjustmenttothediecentreofpressure可以更好的調節(jié)模具的中心受力Remarkablewearreduction明顯減少設備磨損情況Machinelubricationsaving減少機器潤滑Simplerandfasterdiesettingoperations更快更簡單實現模具設定操作CaseStudiesAutomotive汽車工業(yè)實際案例分析Since1969ITALPRESSE,hasdevelopedanddeliveredhundredsofauto-cells,mainlywiththeautomotiveO.E.M.andTier1.從1969年開始，ITALPRESSE已經為汽車工業(yè)OEM和整車廠商制造生產了數百套全自動壓鑄生產單元。Inthenextpagessomecase-historiesshowingcompletecellswhereItalpresseas“onesolesupplier”wasinchargefortheentireturnkeyproject.我們將在以下幾個頁面為您介紹ITALPRSSE的實際交鑰匙工程案例，并向您展示ITALPRESSE“做一家獨一無二的壓鑄機生產商”的理念。Industriallight照明工業(yè)TFMachineTF機器噸位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：鋁

StructuralCasting結構鑄件

Part:RoofFrame(MercedesSL/SLK)部件：車頂骨架（MercedesSL/SLK）StructuralCastings結構鑄件

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：鎂鋁Turn-keySolution,Process,AutomationOptimization全單元交鑰匙工程，工藝流程最優(yōu)自動化設計StructuralCasting結構鑄件

ItalpresseCellforDoktasItalprese壓鑄單元，客戶：DoktasMachine:IP-3000SC機器型號：IP3000SCCasting:CrossMember-subframe鑄件：汽車副車架Alloy:Silafont36材質：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機器型號：IP2500SCCasting:L4EngineBlock鑄件：L4缸體Alloy:Aluminum材質：鋁Turn-keySolution,Process,AutomationOptimization交鑰匙工程，最優(yōu)工藝設計

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機器型號：IP2500SCCasting:L4EngineBlock產品：L4缸體Alloy:Aluminum材質：鋁Turn-keySolution,ProcessandAutomationOptimization交鑰匙工程，最優(yōu)工藝設計

CaseStory-EngineBlocks案例-缸體壓鑄Clients:KiaMotors,Hyundai,MartinreaMexico客戶：起亞、現代、Martinrea墨西哥Casting:V6EngineBlock產品：V6缸體Alloy:Aluminum材質：鋁Turn-keySolution,ProcessandAutomationOptimization交鑰匙工程，最優(yōu)工藝設計

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機器型號：IP3000-IP3500-TF4000Casting:V6Engineblock產品：V6缸體Alloy:Aluminum材質：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機器型號：IP2500SCCastingType:AutomaticTransmissionCase產品：自動變速箱Alloy:Aluminum材質：鋁

CeramicCoresforSpecialShapeCastings特殊形狀鑄件使用陶瓷鑲件Challenge挑戰(zhàn):HighPressureDiecastingusingCeramicCoresinStructuralandHighIntegrityParts在結構件和完整性要求更高的鑄件壓鑄上使用陶瓷鑲件Study,developmentandindustrializationofaninnovativehighpressurediecastingprocessusingceramiclostcorestoproducestructuralandhighintegritycomplexshapeparts在結構件和復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項目團隊成員:Italpresse,UniversityofBrescia,Lomopress,Costamp,Piq2Italpresse，布雷西亞大學，Lomopress，Costamp,Piq2Benefits優(yōu)點:FinalPartCostReduction:cheapertechnology,noassembly.產品最終成本的減少：更便宜的工藝，無需組裝FreeCoreShapesDesign:hollowandcomplexshapesarepossible,evenwithundercutandsecondarycavities.自由鑲件設計：使空心和復雜的形狀成為可能，甚至可以使用切口和二級縮孔ExcellentHighTemperatureMechanicalProperties:nodeformationduringcastingandsolidificationevenwithlowthicknesscores.優(yōu)秀的高溫機械性能：在鑄造和凝固過程當中不存在變形，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:NoGasProductionDuringCasting:ceramicdoesnotreacttoformgaseswhenheatedbymoltenaluminum在鑄造過程當中沒有氣體產生：陶瓷在加熱過程當中不會產生氣體NoNegativeEffectsonAlloyCorrosionResistance:ceramicistheinert?parexcellence?對金屬耐蝕性不會產生負面影響：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:LowCost:bothforrawmaterialandprocessingequipment.更低成本：無論是原料還是工藝設備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：可以使用高壓水，振砂技術或者其他根據鑲件形狀和其復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使用意特中型設備設計生產復雜形狀鑄件，并對其自動化應用進行研究工作COSTAMPonIPLargeSizeMachine:Development,reengineeringandproductionofanautomotivestructuralpart.COSTAMP使用意特大型設備設計生產汽車結構件CeramicCoresforSpecialShapeCastings特殊形狀鑄件使用陶瓷鑲件Highmechanicalproperties:機械性能很高Flexuralstrength(Rf)彎曲強度（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在生產中進行測試

DieCastingDie壓鑄模具Casting鑄件Finishedparts最終產品Protot