ITALPRESSE TF无曲拐两板机

InnovativeDevelopmentsandTechnologyImprovementsinHighPressureDieCasting高压压铸的创新发展与技术进步ChinaDieCastingDevelopmentForum亚太地区压铸工业发展论坛(GuangdongModernInternationalExhibitionCenterHoujie,Dongguan)September16th-17th,2013Speaker:Mr.MaurizioCordova演讲人：意特全球销售总监MaurizioCordova先生FullVersionAvailableonRequest:maurizio.cordova@italpresse.it

Summary概述:Technicalcomparebetween2and3platendiecastingmachine

两板机与三板机的技术比较

-LatestadvancementswithCeramicCoresforspecialshapecastings

带陶瓷芯特殊形状铸件的最新发展Casestudiesandapplications实例分析与应用:

Structuralandsafetyautomotiveparts

汽车结构及安全部件

-FullautomationconceptforEngineBlocks

发动机缸体全自动化

-Transmissioncasesandcomplexgeometrycastings

变速箱及复杂铸件ConventionalThreePlatenMachine传统三板机曲拐系统

REACTIONPLATEN后模座MOVINGPLATEN动模板FIXEDPLATEN定模板TOGGLE曲拐TOGGLESYSTEMCLAMPINGCYLINDER合模油缸TF=“ToggleFree”Machine无曲拐压铸机OverallView透视图CROSSMEMBER横梁MOVINGPLATEN动模板FIXEDPLATEN定模板BLOCKCYLINDERS锁紧油缸HALF-NUTS半圆螺母TIEBAR大杠HALF-NUTS半圆螺母SHIFTPISTONS推进活塞TF=“ToggleFree”Machine无曲拐压铸机MachineClosing机器合模3.Half-nutsclosing半圆螺母闭合2.Movingplatenshift动模板移动1.FromDCM“opened”…开模4.Blockcylinderspressurization锁紧油缸施压

TF=“ToggleFree”Machine无曲拐压铸机MachineOpening机器开模2.Half-nutsre-positioning半圆螺母重新定位3.Half-nutsopening半圆螺母打开4.Movingplatenshift动模板移动1.Blockcylindersdepressurization

锁紧油缸卸压TFvsTogglecomparison有无曲拐的对比Systemrigiditycalculations整体刚度计算LALAEβE

=ELASTICMODULUS弹性系数β

=COMPRESSIBILITYMODULUS压缩系数TFMACHINE无曲拐TOGGLEMACHINE有曲拐A

=UTILESECTION有用截面L

=COMPONENTLENGTH组件长度TFvsTogglecomparison有无曲拐的对比Systemrigiditycalculations整体刚度计算E

=ELASTICMODULUS弹性系数β

=COMPRESSIBILITYMODULUS压缩系数TFMACHINE无曲拐TOGGLEMACHINE有曲拐THERIGIDITYREFERREDTOAPARTICULARSYSTEMONLYDEPENDSONTHESYSTEMITSELFANDNOTONEXTERNALCONDITIONS系统刚性取决于系统本身，而不受外部条件影响A

=UTILESECTION有用截面L

=COMPONENTLENGTH组件长度TFvsTogglecomparison有无曲拐的比较Systemrigidityresults系统刚性结果机器刚性机器合模力

TFvsTogglecomparison有无曲拐的比较Diecompressioncalculations模具压力计算Referencedie:模具参数B

=TIEBARSCLEARANCE大杠间隙L

=AVERAGEDIEHEIGHT平均模具高度A

=UTILESECTION有用截面E

=ELASTICMODULUS弹性系数BBLABoundaryconditions:分界条件Fext

=NOMINALMACHINECLAMPINGFORCE正常机器合模力TFvsTogglecomparison有无曲拐的比较Diecompressionresults模具受力分析伸长率（mm）TFvsTogglecomparison有无曲拐的比较Diecompressionresults模具受力分析模具受力机器合模力TFvsTogglecomparison有无曲拐的比较Operativeconditions设备运转情况OVERALLDIMENSIONS设备总体尺寸机器长度机器锁模力TFvsTogglecomparison有无曲拐的比较Operativeconditions设备运转情况Betteradaptationcapacitytothediedeformationswhilediecasting在压铸的应用上，对于模具的形变具有更好的适应性Moreuniformstressdistributiononmechanicalcomponents(mainlydieandplatens)更均匀的受力分配，包括模具和模板Bettermachineadjustmenttothediecentreofpressure可以更好的调节模具的中心受力Remarkablewearreduction明显减少设备磨损情况Machinelubricationsaving减少机器润滑Simplerandfasterdiesettingoperations更快更简单实现模具设定操作CaseStudiesAutomotive汽车工业实际案例分析Since1969ITALPRESSE,hasdevelopedanddeliveredhundredsofauto-cells,mainlywiththeautomotiveO.E.M.andTier1.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。Inthenextpagessomecase-historiesshowingcompletecellswhereItalpresseas“onesolesupplier”wasinchargefortheentireturnkeyproject.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。Industriallight照明工业TFMachineTF机器吨位1000tonsCastingweight铸件重量8kilosDiecaster压铸厂商Customer最终客户800mm400mmCaseStudy–TF-1000案例分析——TF1000CaseStudy:TF-1350案例分析：TF1350Client:BDW客户：BDWCasting:“Topf1”forHPGetriebe铸件：变速箱外壳“Topf1”，HPGeriebe公司Alloy:Aluminum铸件材质：铝

StructuralCasting结构铸件

Part:RoofFrame(MercedesSL/SLK)部件：车顶骨架（MercedesSL/SLK）StructuralCastings结构铸件

ItalpresseCellforDaimlerItalprese压铸单元，客户：Daimler

InProductionwithTF2150-3000–4000,TF2150-3000-4000压铸单元Casting:RoofFrame铸件：车顶骨架Alloy:MagnesiumandAluminum材质：镁铝Turn-keySolution,Process,AutomationOptimization全单元交钥匙工程，工艺流程最优自动化设计StructuralCasting结构铸件

ItalpresseCellforDoktasItalprese压铸单元，客户：DoktasMachine:IP-3000SC机器型号：IP3000SCCasting:CrossMember-subframe铸件：汽车副车架Alloy:Silafont36材质：硅铝合金36

TheLay-OutConceptbasedon2500tonDCM

2500吨压铸单元布局图CaseStory-EngineBlocks案例：缸体压铸Client:KavianBaris客户：KavianBarisMachine:IP-2500SC机器型号：IP2500SCCasting:L4EngineBlock铸件：L4缸体Alloy:Aluminum材质：铝Turn-keySolution,Process,AutomationOptimization交钥匙工程，最优工艺设计

CaseStory-EngineBlocks案例-缸体压铸Client:NemakChina,India,Poland,Brasil.客户：Nemak中国、印度、波兰、巴西Machine:IP-2500SC机器型号：IP2500SCCasting:L4EngineBlock产品：L4缸体Alloy:Aluminum材质：铝Turn-keySolution,ProcessandAutomationOptimization交钥匙工程，最优工艺设计

CaseStory-EngineBlocks案例-缸体压铸Clients:KiaMotors,Hyundai,MartinreaMexico客户：起亚、现代、Martinrea墨西哥Casting:V6EngineBlock产品：V6缸体Alloy:Aluminum材质：铝Turn-keySolution,ProcessandAutomationOptimization交钥匙工程，最优工艺设计

CaseStory–EgineBlocks案例-缸体压铸

(MartinreaMexico,BrazilandGermany客户：Marinrea墨西哥，巴西和德国）Client:Martinrea

Mexico,BrazilandGermany客户：Marinrea

墨西哥，巴西和德国Machine:IP3000-IP3500-TF4000机器型号：IP3000-IP3500-TF4000Casting:V6Engineblock产品：V6缸体Alloy:Aluminum材质：铝

CompleteCellSolutionsforLargeAutomotiveParts

(TransmissionCase,OilSump,Crankcase,ClutchHousing).

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:-MartinreaBrazilMartinrea巴西-FPAlu(Eurocast)-ShaanxiFastAutoDrive陕西法士特-GeneralMotorsKorea通用韩国-Co.Stamp科斯坦普

CaseStory案例

TransmissionCase变速箱Client:GM客户：GMMachineType:IP2500机器型号：IP2500SCCastingType:AutomaticTransmissionCase产品：自动变速箱Alloy:Aluminum材质：铝

CeramicCoresforSpecialShapeCastings特殊形状铸件使用陶瓷镶件Challenge挑战:HighPressureDiecastingusingCeramicCoresinStructuralandHighIntegrityParts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,developmentandindustrializationofaninnovativehighpressurediecastingprocessusingceramiclostcorestoproducestructuralandhighintegritycomplexshapeparts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ProjectTeam项目团队成员:Italpresse,UniversityofBrescia,Lomopress,Costamp,Piq2Italpresse，布雷西亚大学，Lomopress，Costamp,Piq2Benefits优点:FinalPartCostReduction:cheapertechnology,noassembly.产品最终成本的减少：更便宜的工艺，无需组装FreeCoreShapesDesign:hollowandcomplexshapesarepossible,evenwithundercutandsecondarycavities.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ExcellentHighTemperatureMechanicalProperties:nodeformationduringcastingandsolidificationevenwithlowthicknesscores.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CeramicCoresforSpecialShapeCastings特殊形状铸件使用陶瓷镶件Benefits优点:NoGasProductionDuringCasting:ceramicdoesnotreacttoformgaseswhenheatedbymoltenaluminum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NoNegativeEffectsonAlloyCorrosionResistance:ceramicistheinert«parexcellence»对金属耐蚀性不会产生负面影响：陶瓷是惰性的Closedshapecasting:higherstiffnessofparts封闭形状铸造：可以使铸件的刚度更高CeramicCoresforSpecialShapeCastings特殊形状铸件使用陶瓷镶件Benefits优点:LowCost:bothforrawmaterialandprocessingequipment.更低成本：无论是原料还是工艺设备EnvironmentFriendly:removedcoresareaninertandcanbereusedintheprocessitselforinthecivilbuildingfield.更好的环保性：惰性镶件具有可移除性，并且可以循坏使用VariousDecoringTechniques:highpressurewaterjet,sandblastingorotherinnovativeprocessesaccordingtocoreshapeandcomplexity.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CeramicCoresforSpecialShapeCastings特殊形状铸件使用陶瓷铸件TheProject项目情况:LOMOPRESSonIPMidSizeMachine:Development,engineeringandproductionofacomplexshapewaterintakemanifoldforautomotiveapplications.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COSTAMPonIPLargeSizeMachine:Development,reengineeringandproductionofanautomotivestructuralpart.COSTAMP使用意特大型设备设计生产汽车结构件CeramicCoresforSpecialShapeCastings特殊形状铸件使用陶瓷镶件Highmechanicalproperties:机械性能很高Flexuralstrength(Rf)弯曲强度（Rf）Pressureresistance(P)耐压性Stiffness(YoungModulusE)刚度-Rf:4–60MPa(ondemand)-P>1500bar;-E>6GPaSimulation:vIngate=55m/s;E=4GPa(Stiffnessofshellsandcore)CeramicCoresProperties陶瓷镶件性能MaProfSAS:Projectpartner,carriesthepatentoftheceramiccores(PCT/IB2010/002918)MaProfSAS：项目合作伙伴，持有陶瓷镶件的专利（PCT/IB2010/002918)CeramicCoresforSpecialShapeCastings特殊形状铸件使用陶瓷镶件

DifferentTestsinProduction在生产中进行测试

DieCastingDie压铸模具Casting铸件Finishedparts最终产品Protot