Suzhou Xinsen Precision Casting Co.,Ltd
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    Add: No.238, Qiushe Road, Qiushe Industrial Park, Tongli Town, Wujiang District, Suzhou City, Jiangsu, 215200, P.R.China

    Tel: 86-512-63375886-608

    86-13732656777

    Fax: 86-512-63370558

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    Email: szxsjm@sohu.com

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Automobile Castings Lightweight And High Performance

It is one of the oldest metal forming methods. About 15% to 20% of the auto parts are castings produced by different casting methods. These castings are mainly key components of the power system and important structural components.

At present, Europe and the United States automobile industry developed countries, automobile casting production technology is advanced, product quality is good, high production efficiency, environmental pollution. Casting raw and auxiliary materials have been formed serialization and standardization, the entire production process has been achieved mechanization, automation and intelligence. These countries generally use digital technology to improve the level of casting process design, casting scrap rate of about 2% to 5%, and has established a multinational service system and network technology support. In contrast, although China's automobile castings larger output, but most of them are added value and low technical content, the structure is relatively simple black castings, and the gap between foreign level. This article mainly discusses the development direction of automobile casting and automobile technology from the development demand of automobile energy saving and environmental protection.

1 car casting the direction of development

1.1 integrated design of automotive castings

    With the automotive energy saving and reduce the cost of production requirements continue to increase, make full use of the advantages of casting, the original stamping, welding, forging and casting forming several parts, through reasonable design and structural optimization, to achieve integrated parts casting Forming, can effectively reduce the weight of parts and reduce unnecessary processing technology, in order to achieve the weight of parts and high performance.

    To replace the welding bridge shell and with axle casing cast axle shell of the new products to achieve the integrated casting casting, make full use of the advantages of casting. At present, the main form of the common cast axle housing is to press the seamless steel pipe at both ends of the axle housing as the axle casing and fix the bridge shell with the pin. To further improve the strength of the axle housing, stiffness and simplify the process, FAW Group developed a direct axle casing in the casting axle casing integrated axle casing, which is characterized by reduced processing difficulty, more cost reduction, axle housing The structure tends to be simple, and the axle shell is better, can be made of complex and ideal shape, wall thickness can be changed, can be the ideal stress distribution, its strength and stiffness are large, reliable. Due to the integration of the axle casing, the casting size is significantly increased and the casting is 2 258 mm long and its weight is more than 200 kg. In view of the characteristics of this integrated casting, enterprises have established a dedicated production line to ensure production.

The development trend of automobile casting integration is more obvious in the development of nonferrous alloy castings. In order to make full use of the casting process to achieve the characteristics of the production of complex structural castings, there have been integrated design of the door panels, seat skeleton, dashboard skeleton, front frame and firewall and other integrated design of high-pressure castings, the size significantly larger than the current production Casting, the need for 4 000 ~ 5 000 t or even larger tonnage die-casting machine for production.

1.2 The weight of automotive castings

       To ensure the strength and safety of the car under the premise of the car as much as possible to reduce the quality of the preparation, to achieve lightweight, thereby enhancing the vehicle's power, reduce fuel consumption and reduce exhaust pollution. The quality of the vehicle is reduced by 100 kg and the fuel consumption per 100 km can be reduced by 0.3 to 0.6 L. If the vehicle weight is reduced by 10%, the fuel efficiency can be increased by 6% to 8%. With the needs of environmental protection and energy conservation, the weight of the car has become the world's automobile development trend, the weight of automotive castings has become one of the important direction of development of automotive castings.

1.2.1 Lightweight design of automobile castings

       Due to the overall safety factor of castings, equal thickness design is one of the main design methods of automobile casting. However, the main drawback of the isometric design is that the structural performance can not be fully exploited and the weight of the casting is increased. Using CAE analysis, topology optimization and other means to optimize the design of parts, so that parts of the stress value of various parts close to the various parts of the wall thickness is inconsistent, small parts of the thinner material thickness or not to reduce the parts the weight of. Taking into account the casting forming can achieve the formation of complex structure castings, can achieve a variety of irregular shaped cross-section. Design, the use of CAE or topology optimization and other means of stress analysis of parts. According to the distribution of forces, determine the shape of the parts and the specific local material thickness. Through the casting reinforcement, digging holes and thickening, can greatly reduce the weight of parts.

       Precision Casting Co., Ltd. to optimize the design of commercial vehicles before and after the casting shape comparison, showing the initial weight of castings 6.6 kg, which is designed for a typical thick design. After a series of lightweight design methods such as reinforcement, digging and variable cross-section, the casting weight becomes 3.0 kg and the weight loss is more than 50%.


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Address: No.238, Qiushe Road, Qiushe Industrial Park, Tongli Town, Wujiang District, Suzhou City, Jiangsu, 215200, P.R.China
Tel: +86-512-633758+86-608
 Fax:86-512-63370558
 E-mail:szxsjm@sohu.com
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