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

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

- Latest advancements with Ceramic Cores for special shape castings 带陶瓷芯特殊形状铸件的最新发展

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

Conventional Three Platen Machine 传统三板机

曲拐系统曲拐系统

REACTIONREACTIONPLATENPLATEN后模座后模座

MOVINGMOVINGPLATENPLATEN动模板动模板

FIXEDFIXEDPLATENPLATEN定模板定模板

TOGGLETOGGLE 曲拐曲拐

TOGGLE SYSTEMTOGGLE SYSTEM

CLAMPINGCLAMPINGCYLINDERCYLINDER合模油缸

TF = “Toggle Free” Machine 无曲拐压铸机

Overall View 透视图

CROSSCROSSMEMBERMEMBER横梁横梁

MOVINGMOVINGPLATENPLATEN动模板动模板

FIXEDFIXEDPLATENPLATEN定模板定模板

BLOCK CYLINDERSBLOCK CYLINDERS锁紧油缸锁紧油缸

HALF-NUTSHALF-NUTS 半圆螺母半圆螺母TIE BARTIE BAR

大杠 大杠

HALF-NUTSHALF-NUTS半圆螺母半圆螺母

SHIFT SHIFT PISTONSPISTONS推进活塞推进活塞

TF = “Toggle Free” Machine 无曲拐压铸机Machine Closing Machine Closing 机器合模机器合模

3. Half-nuts closing 3. Half-nuts closing 半圆螺母闭合半圆螺母闭合

2. Moving platen shift 2. Moving platen shift 动模板移动动模板移动1. From DCM “opened”… 1. From DCM “opened”… 开模开模

4. Block cylinders pressurization4. Block cylinders pressurization

锁紧油缸施压锁紧油缸施压

TF = “Toggle Free” Machine 无曲拐压铸机Machine Opening Machine Opening 机器开模机器开模

2. Half-nuts re-positioning 2. Half-nuts re-positioning 半圆螺母重新定半圆螺母重新定位位

3. Half-nuts opening 3. Half-nuts opening 半圆螺母打开半圆螺母打开 4. Moving platen shift 4. Moving platen shift 动模板移动动模板移动

1. Block cylinders depressurization1. Block cylinders depressurization

锁紧油缸卸压锁紧油缸卸压

TF vs Toggle comparison 有无曲拐的对比System rigidity calculations System rigidity calculations 整体刚度计算整体刚度计算

L

A

L

A

E β

EE = ELASTIC MODULUS= ELASTIC MODULUS 弹性系数弹性系数

ββ = COMPRESSIBILITY MODULUS= COMPRESSIBILITY MODULUS 压缩系数压缩系数

TF MACHINETF MACHINE 无曲拐无曲拐 TOGGLE MACHINETOGGLE MACHINE 有曲拐有曲拐

AA = UTILE SECTION= UTILE SECTION 有用截面有用截面

LL = COMPONENT LENGTH= COMPONENT LENGTH 组件长度组件长度

TF vs Toggle comparison 有无曲拐的对比System rigidity calculationsSystem rigidity calculations 整体刚度计整体刚度计算算

EE = ELASTIC MODULUS= ELASTIC MODULUS 弹性系数弹性系数

ββ = COMPRESSIBILITY MODULUS= COMPRESSIBILITY MODULUS 压缩系数压缩系数

TF MACHINETF MACHINE 无曲拐无曲拐 TOGGLE MACHINETOGGLE MACHINE 有曲拐有曲拐

THE RIGIDITY REFERRED TO A PARTICULARTHE RIGIDITY REFERRED TO A PARTICULAR

SYSTEM ONLY DEPENDS ON THE SYSTEM ITSELFSYSTEM ONLY DEPENDS ON THE SYSTEM ITSELF

AND NOT ON EXTERNAL CONDITIONSAND NOT ON EXTERNAL CONDITIONS

系统刚性取决于系统本身，而不受外部条件影响系统刚性取决于系统本身，而不受外部条件影响

AA = UTILE SECTION= UTILE SECTION 有用截面有用截面

LL = COMPONENT LENGTH= COMPONENT LENGTH 组件长度组件长度

TF vs Toggle comparison 有无曲拐的比较System rigidity resultsSystem rigidity results 系统刚性结果系统刚性结果

机器刚性机器刚性

机器合模力机器合模力

TF vs Toggle comparison 有无曲拐的比较Die compression calculationsDie compression calculations 模具压力计算模具压力计算

Reference die:Reference die:模具参数模具参数BB = TIE BARS CLEARANCE= TIE BARS CLEARANCE 大杠间隙大杠间隙

LL = AVERAGE DIE HEIGHT= AVERAGE DIE HEIGHT 平均模具高度平均模具高度

AA = UTILE SECTION= UTILE SECTION 有用截面有用截面

EE = ELASTIC MODULUS= ELASTIC MODULUS 弹性系数弹性系数

B

B

L

A

Boundary conditions: Boundary conditions: 分界条件分界条件FFextext = NOMINAL MACHINE CLAMPING FORCE= NOMINAL MACHINE CLAMPING FORCE 正常机器合模力正常机器合模力

TF vs Toggle comparison 有无曲拐的比较Die compression resultsDie compression results 模具受力分析模具受力分析

伸长率（ mm ）

TF vs Toggle comparison 有无曲拐的比较Die compression resultsDie compression results 模具受力分析模具受力分析

模具受力

机器合模力

TF vs Toggle comparison 有无曲拐的比较Operative conditions Operative conditions 设备运转情况设备运转情况

OVERALL DIMENSIONSOVERALL DIMENSIONS 设备总体尺寸

机器长度

机器锁模力

TF vs Toggle comparison 有无曲拐的比较Operative conditionsOperative conditions 设备运转情设备运转情况况1.1. Better Better adaptationadaptation capacity to the die deformations while diecasting capacity to the die deformations while diecasting 在压铸的应用上，在压铸的应用上，

对于模具的形变具有更好的适应性对于模具的形变具有更好的适应性

2.2. More More uniformuniform stress distribution on mechanical components (mainly die and platens) stress distribution on mechanical components (mainly die and platens)

更均匀的受力分配，包括模具和模板更均匀的受力分配，包括模具和模板

3.3. Better machine adjustment to the die Better machine adjustment to the die centre of pressurecentre of pressure 可以更好的调节模具的中心受力可以更好的调节模具的中心受力

4.4. Remarkable Remarkable wearwear reduction reduction 明显减少设备磨损情况明显减少设备磨损情况

5.5. Machine lubrication Machine lubrication saving saving 减少机器润滑减少机器润滑

6.6. Simpler and faster Simpler and faster die setting die setting operationsoperations 更快更简单实现模具设定操作更快更简单实现模具设定操作

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。

Industrial lightIndustrial light 照明工业照明工业

TF MachineTF 机器吨位1000 tons

Casting weight 铸件重量 8 kilos

Diecaster 压铸厂商

Customer 最终客户

800 mm

400 mm

Case Study – TF-1000 案例分析—— TF1000

Case Study: TF-1350 案例分析： TF1350

Client: BDW Client: BDW 客户：客户： BDWBDW

Casting: “Topf 1” for HP GetriebeCasting: “Topf 1” for HP Getriebe 铸件：变速箱外壳 “铸件：变速箱外壳 “ TopfTopf

11” ” ，， HP Geriebe HP Geriebe 公司公司 Alloy: Aluminum Alloy: Aluminum 铸件材质：铝铸件材质：铝

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

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,In Production with TF 2150 - 3000 – 4000,

TF2150-3000-4000TF2150-3000-4000 压铸单元压铸单元 Casting: Roof FrameCasting: Roof Frame

铸件：车顶骨架铸件：车顶骨架

Alloy: Magnesium and AluminumAlloy: Magnesium and Aluminum

材质：镁铝材质：镁铝 Turn-key Solution, Process, Automation Turn-key Solution, Process, Automation

OptimizationOptimization

全单元交钥匙工程，工艺流程最优自动化设计全单元交钥匙工程，工艺流程最优自动化设计

Structural Casting 结构铸件Italpresse Cell for Doktas Italprese 压铸单元，客户： Doktas

Machine: IP-3000SC Machine: IP-3000SC

机器型号：机器型号： IP3000SCIP3000SC

Casting: Cross Member-sub frameCasting: Cross Member-sub frame

铸件：汽车副车架铸件：汽车副车架

Alloy: Silafont 36 Alloy: Silafont 36 材质：硅铝合金材质：硅铝合金3636

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

Case Story - Engine Blocks 案例：缸体压铸

Client: Kavian BarisClient: Kavian Baris 客户：客户： Kavian BarisKavian Baris

Machine: IP-2500SCMachine: IP-2500SC 机器型号：机器型号： IP2500SCIP2500SC

Casting: L4 Engine BlockCasting: L4 Engine Block 铸件：铸件： L4L4 缸体缸体

Alloy: AluminumAlloy: Aluminum 材质：铝材质：铝

Turn-key Solution, Process, Automation OptimizationTurn-key Solution, Process, Automation Optimization 交交钥匙工程，最优工艺设计钥匙工程，最优工艺设计

Case Story - Engine Blocks 案例 - 缸体压铸

Client: Nemak China, India, Poland, Brasil.Client: Nemak China, India, Poland, Brasil. 客户：客户：NemakNemak 中国、印度、波兰、巴西中国、印度、波兰、巴西

Machine: IP-2500SCMachine: IP-2500SC 机器型号：机器型号： IP2500SCIP2500SC

Casting: L4 Engine BlockCasting: L4 Engine Block 产品：产品： L4L4 缸体缸体

Alloy: AluminumAlloy: Aluminum 材质：铝材质：铝

Turn-key Solution, Process and Automation OptimizationTurn-key Solution, Process and Automation Optimization 交钥匙交钥匙工程，最优工艺设计工程，最优工艺设计

Case Story - Engine Blocks 案例 - 缸体压铸Clients: Kia Motors, Hyundai, Martinrea MexicoClients: Kia Motors, Hyundai, Martinrea Mexico 客户：起亚、客户：起亚、现代、现代、 Martinrea Martinrea 墨西哥墨西哥

Casting: V6 Engine BlockCasting: V6 Engine Block 产品：产品： V6V6 缸体缸体

Alloy: AluminumAlloy: Aluminum 材质：铝材质：铝

Turn-key Solution, Process and Automation OptimizationTurn-key Solution, Process and Automation Optimization 交交钥匙工程，最优工艺设计钥匙工程，最优工艺设计

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 GermanyClient: Martinrea Mexico, Brazil and Germany 客户： Marinrea 墨西哥，巴西和德国

Machine: IP 3000 - IP 3500 - TF 4000 Machine: IP 3000 - IP 3500 - TF 4000 机器型号：机器型号： IP3000-IP3500-TF4000IP3000-IP3500-TF4000

Casting: V6 Engine block Casting: V6 Engine block 产品：产品： V6V6 缸体缸体Alloy: AluminumAlloy: Aluminum 材质：铝材质：铝

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）

ClientsClients 客户客户 ::

- Martinrea Brazil Martinrea - Martinrea Brazil Martinrea 巴西巴西

- FP Alu (Eurocast) - FP Alu (Eurocast)

- Shaanxi Fast Auto Drive - Shaanxi Fast Auto Drive 陕西法士特陕西法士特

- General Motors Korea - General Motors Korea 通用韩国通用韩国

- Co.Stamp - Co.Stamp 科斯坦普科斯坦普

Case Story 案例Transmission Case 变速箱

Client: GM Client: GM 客户：客户： GMGM

Machine Type: IP 2500 Machine Type: IP 2500 机器型号：机器型号： IP2500SCIP2500SC

Casting Type: Automatic Transmission CaseCasting Type: Automatic Transmission Case

产品：自动变速箱产品：自动变速箱

Alloy: AluminumAlloy: Aluminum 材质：铝材质：铝

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, Piq2Italpresse ，布雷西亚大学， Lomopress ， Costamp,Piq2

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

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

Ceramic Cores for Special Shape Castings特殊形状铸件使用陶瓷镶件

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

Ceramic Cores for Special Shape Castings特殊形状铸件使用陶瓷铸件

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

Ceramic Cores for Special Shape Castings特殊形状铸件使用陶瓷镶件

High mechanical properties:High mechanical properties:机械性能很高机械性能很高- Flexural strength (R f ) Flexural strength (R f ) - 弯曲强度（弯曲强度（ RfRf ））- Pressure resistance (P)Pressure resistance (P)- 耐压性耐压性- Stiffness (Young Modulus E)Stiffness (Young Modulus E)- 刚度刚度- Rf : 4 – 60 MPa (on demand)- Rf : 4 – 60 MPa (on demand)- P > 1500 bar;- P > 1500 bar;- E > 6 GPa- E > 6 GPa

Simulation: vIngate= 55 m/s; E = 4 GPa (Stiffness of shell sand core)

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)

Ceramic Cores for Special Shape Castings特殊形状铸件使用陶瓷镶件

Different Tests in Production 在生产中进行测试

Die Casting Die压铸模具

Die Casting Die压铸模具

Casting 铸件Casting 铸件

Finished parts 最终产品Finished parts 最终产品

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

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

Ceramic Cores for Special Shape Castings特殊铸件使用陶瓷镶件

ConclusionsConclusions 结论结论- The “TF” Innovative Toggle Free Machine The “TF” Innovative Toggle Free Machine is the Answer to is the Answer to

Improve the Diecasting Process and satisfy the latest Improve the Diecasting Process and satisfy the latest

- TFTF 革新型无曲拐压铸机将是最新压铸工艺的发展方向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.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结构件的需求将促使陶瓷镶件的研究进入新的阶段

- Significant Experience, Significant Experience, Case Histories proving Reliable Case Histories proving Reliable

Equipment, Constant Casting Quality and Equipment Equipment, Constant Casting Quality and Equipment

Efficiency Efficiency 通过以往的经验，案例证明了设备的可靠性，更高通过以往的经验，案例证明了设备的可靠性，更高的铸件质量，以及设备的高效的铸件质量，以及设备的高效

- The “TF” Solutions The “TF” Solutions grant a Reduction of Mechanical grant a Reduction of Mechanical

Components, Better Balance and Less Maintenance.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更少的维修保养

- Elevated Automation Elevated Automation and Advanced Electronic Solutions for and Advanced Electronic Solutions for

a User-Friendly Operation. a User-Friendly Operation.

- 更高的自动化要求以及更友好的电气人机界面更高的自动化要求以及更友好的电气人机界面

感谢您的关注。

Thank you for your attention.Thank you for your attention.

www.italpressegroup.comwww.italpressegroup.com