yamaha cf eng

7/25/2019 Yamaha Cf Eng

1/8

Select Language

Home

Yamaha Global Links

Japanese Site

Global Home

Global News Center

2002

A new die-cast method for manfactrin! inno"ation #Yamaha C$ Alminm

%ie Castin! &echnolo!'# %e"eloped (akin! possible the mass prodction of

lar!e bt thin alminm die-cast parts

A new die-cast method formanfactrin! inno"ation #Yamaha C$Alminm %ie Castin! &echnolo!'#%e"eloped (akin! possible the mass

search
http://void%280%29/http://void%280%29/http://global.yamaha-motor.com/http://global.yamaha-motor.com/link/http://global.yamaha-motor.com/jp/http://global.yamaha-motor.com/http://global.yamaha-motor.com/news/http://global.yamaha-motor.com/news/2002/http://global.yamaha-motor.com/http://global.yamaha-motor.com/link/http://global.yamaha-motor.com/jp/http://global.yamaha-motor.com/http://global.yamaha-motor.com/news/http://global.yamaha-motor.com/news/2002/http://void%280%29/


2/8

prodction of lar!e bt thin alminmdie-cast parts

February 05, 2002

Yamaha Motor Co., Ltd. (YMC) has succeeded in the development o a ne!

manuacturin" technolo"y called the #Yamaha CF $luminum %ie Castin"

&echnolo"y' that enables the mass production o lar"e but thin aluminum diecast

parts in an environmentriendly, lo!cost !ay that !ill contribute si"niicantly to

manuacturin" innovation. CF %ie Castin" * Controlled Fillin" %ie Castin"

$luminum die castin" is a technolo"y that brin"s e+cellent manuacturin" productivit

to aluminum parts, !ith their inherent ualities o li"ht !ei"ht, rust resistance and

recyclables. $s a result, diecast aluminum parts are used in lar"e numbers in

motorcycle en"ines and chassis as !ell as outboard motors. -o!ever, !ith

conventional die castin" there has al!ays been a limit to the thinness o sections in a

cast piece in relationship to its overall sie. &hat is !hy it has lon" been diicult in th

industry to produce diecast parts that are both lar"e overall and thin in some sections

Furthermore, !ith the present trend to!ard environmental concerns resultin" in the sh

to /stroe en"ines and the addition o e+haustcleanin" devices !hich increase both

the !ei"ht and number o parts or uture models, it is believed that the eys to

manuacturin" innovation !ill be li"htenin" technolo"ies in combination !ith measur

that reduce cost and improve uel eiciency.

&he ne!ly developed #Yamaha CF $luminum %ie Castin" &echnolo"y' is a process

that enables mass production o aluminum diecast parts that are both lar"e and thin insections, thus main" it a technolo"y that ans!ers today1s social needs by enablin" th

production o li"hter products !ith e!er parts. Focusin" on improvin" the lo!

characteristics o the molten aluminum as it is poured into the metallic mold (die),

Yamaha1s ne! technolo"y "reatly improves the smoothness o the lo! into the die by

() increasin" the vacuum inside the die, (2) re"ulatin" the temperature o the die and


3/8

(3) improvin" the in4ection speed o the molten aluminum. &he combined eects o

these measures enable the mass production o hi"huality diecast aluminum parts !

an airintrusion rate (cause o air bubbles) o about oneith that o conventional die

castin".

&he introduction o this ne! technolo"y to the manuacturin" process can result in

about a 30 reduction in part !ei"ht and 60 reduction in the number o parts

necessary. Furthermore, the reduction in the amount o aluminum used and the

simpliication o the manuacturin" process !ill brin" an estimated 30 reduction in

cost compared to the conventional die castin" method. $nd, because it does not reuir

specialied aluminum alloys, this technolo"y can be readily transerred to overseas

manuacturin" bases on the condition that the metallic molds be chan"ed as !ell.

$t Yamaha !e !ill apply o this technolo"y to a !ide ran"e o products such as

motorcycles and outboard motors.

Comparison o CF $luminum %ie Castin" and other conventional diecast methods

Minimum piece thicness(m


4/8

Summary of the Technology

%ue to the controlled conditions under !hich the molten aluminum is in4ected into th

metallic mold (die) at hi"h speeds and hi"h pressure in conventional hi"hpressure di

castin", a certain amount o air and o+ides inevitably enter alon" !ith the aluminum,

resultin" in "eneratin" air bubbles in the inal cast metal. $s a result, there !as a limi

to ho! thin sections o the cast parts could be and ho! sharp the curves in the parts

could be. &his !as a !eaness o the conventional die castin" method that let room

improvement. &he #Yamaha CF $luminum %ie Castin" &echnolo"y' is the result o

development eorts ocused on the #shapin" technolo"y' applied to aluminum dieca

parts in order to improve on this !eaness.

&he technical ocus in developin" this ne! method !as to optimie the lo!

characteristics o the molten aluminum to obtain the best possible lo! into the die in

the short time beore the aluminum be"ins to solidiy, !ith optimum evenness in theinal lie o the aluminum beore it hardens.

&o achieve this, !e built on the technolo"ical base acuired rom our lon" years o

e+perience in vacuum aluminum die castin" and added an e+clusive ne! method or

improvin" the completeness o the vacuum in the die !hich also made possible more

precise control o the various aspects o the castin" process. 7peciically speain", !e

optimied the conditions o the molten aluminum in4ection into the die by ()

introducin" an e+clusively developed ne! type o seal material or sealin" the die par

to"ether to increase the completeness o the vacuum inside the mold and reduce the a

resistance (si+ old improvement over conventional method), (2) controllin" the

temperature o the mold in order to achieve a more stable temperature in the molten

aluminum and, (3) increasin" the speed o the molten aluminum in4ection (ive times

over conventional method). &he combined eect o these measures reduced the amou

o air ("ases) in the resultin" cast metal to oneith the amount o the conventional


5/8

method. &his results in a stron"er uality aluminum that, unlie conventional diecast

aluminum, is stron" enou"h to be !elded, !hich in turn maes possible the mass

production o aluminum diecast parts that are both lar"e and thin in relevant sections

&his ne! method maes it possible to manuacture aluminum parts !ith the hi"h

eiciency o hi"hpressure die castin", and !ith stren"th and stretchability eual to

"ravity castin". $lso, this has made it possible to produce the ind o lar"e but thin

aluminum diecast parts that !ere diicult under the conventional die castin" method

Furthermore, since this ne! method enables the mass production o cast aluminum

parts desi"ned or e+treme thinness and more comple+ curves, it !ill su""est ne!

desi"n standards or cast aluminum parts.

Conventional $luminum

%ie castin" &echnolo"y

Yamaha CF $luminum %ie Castin" &echnolo"y

Characteried by () seals inserted bet!een mold

sections to increase vacuum completeness,

(2) stabiliation o the molten aluminum temperature b

controllin" mold temperature,

(3) improved in4ection speed or the molten aluminum


6/8

Reference

Development Background

$mid the increasin" concern or environmental preservation, there has been a rapid

shit to!ard /stroe en"ines or motorcycles and outboard motors, as !ell as the

adoption o emissionsreducin" catalyers and electronic uel in4ection systems. &her


7/8

has also been an increasin" movement to!ard hybrid vehicles, all o !hich has result

in a revolution in vehicle en"ine and chassis desi"n. 8aturally, there is a concern that

these additional systems !ill increase the !ei"ht o en"ines. $ccordin"ly, the ey is t

use li"ht!ei"ht aluminum and li"ht!ei"ht desi"n technolo"ies to cancel out this adde

!ei"ht so that products can maintain past perormance levels or even improve on them

$luminum is about 3/ li"hter than steel and is also e+cellent or castin" thans to it

lo! meltin" point and "ood lo! characteristics. $luminum is also easier to reuse tha

other metals and there is almost no dierence in the uality o the metal produced ro

recycled aluminum compared to ne! stoc. $lso, by combinin" it !ith other metals a

selectin" dierent inds o thermo physical methods, it can be made to it the needs o

dierent uses. &ain" advanta"e o these beneicial ualities, Yamaha uses aluminum many o its products.

9articularly in products lie motorcycles, sno!mobiles and personal !atercrat !ith

!hich customers en4oy the handlin" and the eelin" o #manmachine' unity that

results, !e at Yamaha consider #reducin" !ei"ht' to be an important part o our

manuacturin" innovation process. $nd, one o the !ays !e reduce !ei"ht is by

introducin" aluminum parts. 9resently, the ratio o aluminum (by !ei"ht) in our

outboard motors is about 50, !hile our lar"eclass motorcycles are about /0. $nd

as seen by the act that !e use about 3,000 tons o aluminum a month in our actories

improvin" the uality, the amount, and manuacturin" process o aluminum parts has

vital eect on our products rom their cost to their uality.

$"ainst this bacdrop, Yamaha CF $luminum %ie Castin" &echnolo"y has developed

!ith the result o our research, development and practice o aluminum diecastin" in

order to realie our manuacturin" innovation.


8/8

&his supersport model #Y:F;' is /0

aluminum by !ei"ht.

&he outboard motor is 50

aluminum by !ei"ht.

(9hoto

yamaha cf eng

Documents