Light material reachs processing technique: Use RP technology quantity to produce hollow aluminous cast

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  • source:YIGAN CNC Machining
Japan casts component manufacturer KOIWAI to devoting oneself to RP (Rapid Prototyping, shape quickly) the technology produces medium application in the quantity. This technology and use master mold to undertake production be comparinged can raising precision, realize thin wall cast. As among them one annulus, this company trial-produce undertake to aluminium alloy hollow cast deputy frame. Car and industry use arenaceous model to make normally with the trial-produce cast of aluminous component. Because of similar trial-produce such word that metallic pattern uses in a few production, criterion all up calls in mould cost. And need time to look from delivery place, when using arenaceous model can shorter. In the method that makes arenaceous model, appeared at present a kind of skill that calls a layer to accumulate arenaceous moulding to make technology. This technology does not use master mold to make arenaceous model, a kind when adopt RP device however, namely the layer accumulates device, make arenaceous model directly by three-dimensional CAD data. Compare with original production law photograph, this kind of production law can shorten the time limit for a project that forms cast half. As a result of need not master mold, when be being made accordingly, return but cost of leave out initial stage. The model that also need not have through master mold additionally, pour the tall difficulty such as the model technology, can make the arenaceous model that gives the aleatoric appearance with taller precision. The cast of complex form should pass skilled manual work to form normally, make respectively after fractionation, rise departmental cent agglutinate with adhesive next. And when using a layer to accumulate arenaceous model, differ, an organic whole below the case that can not having fractionation is made finish. KOIWAI basically makes the motor on the motor outside offerring car, the side of a ship and water wait use all sorts of casting component, material is given priority to with aluminium. At present KOIWAI is devoting oneself to a layer to accumulate arenaceous moulding to make a way, and had lay the outstanding achievement of goods actually. Having offerringing preproduction. Distinction uses two kinds of layers to accumulate arenaceous moulding to build law 　 layer to accumulate arenaceous moulding to build a law to be divided roughly accumulate production law and ink jet to make a way for laser layer two kinds. In respect of laser agglomeration law, the name that company of EOS of KOIWAI use Germany makes is " EOSINT-S " device. The laid when the operation a casting is arenaceous with resinous mixture, to the local illuminate laser that wants reservation to come down, make resin molten again caky rise. Next one layer upon layer ground relapses this one operation. In laser not on the share that illuminate reachs, resin won't be molten, casting is arenaceous still assume dispersive position, but relaxed purify. Because can form intensity and the core of housing molding sand is same arenaceous model that use metallic moulding to build, because law of this laser agglomeration is used at be being compared with material and appearance photograph normally,pay attention to the circumstance of intensity more. Nevertheless, after using laser to undertake agglomeration, still need to be put into roast furnace, right whole arenaceous model has agglomeration process 2 times, because of this bellwether time will naturally lengthen. Should make a law can form the largest size to be 750 × the arenaceous model of 350 × 350mm. And in respect of ink jet law, what KOIWAI uses is the name that American PROmetaL company makes is " S-Print " device. When the operation good to the shop with ink jet means thin thin a casting is arenaceous go up the resin with molten eject. Because resinous particle is imperceptible, like mist eject comes out, permeability is very accordingly tall. Next like laser agglomeration law, one layer upon layer ground relapses this one operation, the casting arenaceous purify that will soak without colophony is dropped. Compare with photograph of laser agglomeration law, the strength that place of ink jet law gains is inferior, and the surface also is shown slightly coarse, do not need agglomeration 2 times nevertheless, can shorten accordingly bellwether time. Can make a law most greatly 380 × of 750 × the arenaceous model of 400mm, so two kinds of production laws differ on dimension not quite. KOIWAI is Japan installs two kinds of layers exclusively to accumulate device to make arenaceous model, cast the manufacturer that will accumulate a technology through oneself. After the terrible gain and loss that our company can make a way two kinds in balance, judge to using which kind of making according to the circumstance of the spot. Can make law distinction use to two kinds so, make upper mould and lower mould with ink jet law for instance, make arenaceous core with laser agglomeration law, etc. KOIWAI is used successfully already " S-Print " aluminous to AC4C makings undertook casting, those who cast is the preproduction of inverter crust. The workpiece in the photograph cut one share to be used at filming, can see the complex cooling canalage that by arenaceous core hind of drawing of patterns forms. The dimension of this preproduction is 480 × 320 × 175mm, weight is 5kg. KOIWAI returns trial-produce slightly a few more compressed inverter comes loose hot crust. Dimension is 520 × 320 × 160mm, weight is 4kg. Two components are in above mould was finished with 3 days after obtaining three-dimensional data, finished with 6 days cast. Still made dimension be 300 × additionally 200 × 180mm, weight is 1.

The compressor housing of 5kg. Mould was finished with 2 days after obtaining three-dimensional data, finished in the 4th day cast. KOIWAI is used " EOSINT-S " the crust that is motor to what AC4C undertakes production. Dimension is a diameter 350 × 125mm, weight is 3.

2kg. Still made additionally in case of motor of the longish on axial direction. Dimension is a diameter 280 × 350mm, weight is 2.

5kg. Two components all finished mould with 3 days after obtaining three-dimensional data, finished with 5 days cast. Still can use in addition " SPrint " made cast-iron turbine housing. Dimension is 200 × 200 × 180mm, weight is 2kg. 3 days of time were used to finish mould after obtaining three-dimensional data, finished with 5 days make. Nextpage is used at trial-produce to also be used at the quantity to produce 　 layer to accumulate arenaceous moulding to make a way already is to make preproduction development originally. Want to have CAD data only, even if is a product also can be made, need not prepare master mold. comfortable at trial-produce utility. KOIWAI also buys afore-mentioned equipment to talent is used in trial-produce branch just about. But KOIWAI realizes gradually, if can freely,use the word of these equipment, its special at making a product or trial-produce is too wasteful. Of course, if one ration produces dimensions, production wood model and colophony model can make cost lower. But, even if is nodded evenly to exceed profit and loss and make wooden model and colophony model surely definitely, unwarrantable also the order that obtains the life with these moulds to comparative. And when undertaking administrative to the mould, even devoted equipment reachs man-hour. Such word, even if the quantity produces dimensions to be 2000 / lunar quantity produces a product, KOIWAI also can consider to use a layer to accumulate arenaceous moulding to make a way. Additional, if can make full use of precision is tall the word of this one advantage, the issue that also selects evenly with respect to nonexistent profit and loss. Much obligate have more than needed need not pass to spend if precision is tall, but the wall thick utmost ground is decreased thin, thereby hopeful realizes light simple product. Such word, although throw somehow cost also is worth to use. In using hollow aluminous cast to reduce car 　 to produce a product in the quantity, what KOIWAI considers to apply a layer adequately to accumulate arenaceous moulding to make a way is the hollow part that the automobile body that offers a car and travel part use. First product of the tentative idea is the deputy frame that is used at supporting pensile arm. From the point of the common sense of automobile industry, if the quantity produces the saying with old dimensions, aluminous cast uses metal pattern to make, but hollow a may not is such. If using metal pattern to make arenaceous core, cannot take out after cast, can use arenaceous model only. Want to accumulate arenaceous moulding to build a law to make arenaceous core with the layer that is to say. The setting that selects this part depends on KOIWAI providing some crises to feel as casting manufacturer place. Henceforth EV (electric car) wait predominate, the action of engine decreases probably relatively. At present KOIWAI supplies cast a component to be concerned with engine mostly, existence amount tends reductive is dangerous. And the part that makes automobile body and travel part is different, no matter the car is motivation with what, hopeful appears with the demand with corresponding number. Among them, the reason that KOIWAI devotes oneself to pensile component depends on light quantified effect is tremendous. Inside course of study think generally, reduce the sentence of the weight below reed, can rise operate stability, with reduce photograph of the weight on reed to compare, can achieve the effect of 3 times. But so probable meeting makes cost appears somehow rise. Deputy frame says to be located in below reed with its, be inferior to saying to be located in actually " in reed " , and it is to point to the share that undertakes with lining flexibility is propped up on reed, because this pair of frame can say,be located in relatively " below reed " . In the option that converts processing in aluminium, casting aluminium has an advantage. This is, wait with punch material and plank different, raw material can use circular secondary material. Japan already formed system of organization of resource loop second birth at present, the current metallic ingot on market has nearly 50 ％ to be circular secondary material. With use raw material namely the aluminous look that bauxite has abstracting is compared, secondary aluminium piece can have production with the energy under 5 ％ , if price of the sources of energy is accordingly rising, price competition ability can rise. Current deputy frame is given priority to with the construction of joint coming through soldering after punch armor plate stream. Also be in charge of combination to make through becoming profiled bar with hydraulic pressure sometimes. This component existence converts aluminium alloy in order to come true light quantified trend. Although had appeared to use before this,solder wait for a method to reach plank those who provide material to solder construction and Die Casting combination rises, form hollow precedent, but have not discover cast of hollow an organic whole. Accordingly, KOIWAI tentative idea makes work with city the travel part of high-grade racing bike is an object, looked for a deputy frame. This pairs of frame solders them to rise and be made again after punch armor plate curves steel tube. Can conclude the man-hour that its expend is quite big. KOIWAI made CAD data for premise with can be aimed and be being adjusted the position of this component and pedestal. Occupy according to this next, with layer accumulating arenaceous model made upper mould and lower mould respectively. Whole uses common arenaceous moulding to build, what arenaceous model uses 7 sieves eye is common arenaceous. Arenaceous core accumulates arenaceous moulding to build with the layer, those who use 8 sieves eye is fine arenaceous. Material is AC4C character, cast temperature to be 740 ℃ , average wall thick for 3mm. Undertaking actually casting and made weight is measured after machine tool treatment to needing the part of processing, undertook comparative with the part that provides on practical car. The treatment product of deputy frame is made an appointment with before for 15.

5kg, and aluminous an organic whole casts a product for 8.

9kg. The treatment product of deputy frame is made an appointment with after for 27.

5kg, and aluminous an organic whole casts a product for 14.

5kg. Before, hind deputy frame was reduced considerably respectively 44 ％ and 46 ％ . In addition, KOIWAI returns trial-produce FF (before buy engine, front-wheel drive) of the model before deputy frame. This component from 14.

2kg falls to 6.

9kg, reduced 52 ％ . KOIWAI was in in May 2010 " person and car science and technology are exhibited " on KOIWAI exhibited preproduction of afore-mentioned 3 kinds of deputy frame, undertook introductory to numerous car manufacturer. And also have a firm expressed interest. After deputy frame, the below one task of KOIWAI is automobile body. The target is with hollow means an organic whole casts EV to use small-sized frame. The batteries function of EV still is in development phase at present, want to lengthen continuously travel space, deploy costly batteries in great quantities only or reduce automobile body weight. From the point of current general knowledge, the abidance of EV travel space even is shorter. KOIWAI will set out from the footing of casting manufacturer, assist to solve this one task to offer. Of frame outside side uses metal pattern to make, and the arenaceous core with hollow implementation of in order to accumulates arenaceous model to make through the layer. Although metal pattern cost is higher, but its precision is supereminent. Such, the wall is large when the side outside be being made with respect to can more arenaceous than using model thinner, estimation can be decreased to 2 ～ 2.

5mm. This one arm is thick be the same as with all without exception when using plank to make. Additional, to having the share of joint with the other part that has strength demand, the data that will mix casting to wait for high strenth into steel through local sex will undertake redeeming. This kind of processing comes true very hard when using punch material and board, and here because be,casting can accomplish so. KOIWAI is booked cast installation through improving and have optimal set to casting a condition, establish has a quantity to produce a product to produce production method of the condition. And the strict requirement that produces efficiency and cost to also can satisfy a quantity adequately to produce a car. CNC Milling CNC Machining