EA111曲轴新生产线工艺及铸件质量控制

Technology and Quality Control of Casting of EA111 Crankshaft New Production Line

针对EA111曲轴壳型铸造机械化生产新线出现的工艺和质量问题,进行研究攻关,做了大量的工艺试验和质量改进工作。通过改进EA111曲轴一型四件型壳排气片的结构和冷铁工艺等;改进球化包、机械化浇注包的容积和包衬材料等;改进铁液成分和合金含量等,提高了曲轴的力学性能和质量,使EA111曲轴内废率由20%降低到2%以下,加工外废率由3%降低到0.3%以下。保证和满足了大众公司对曲轴日益增长的产量和质量需求。

Aiming to the process and quality problems in EA111 crank shell casting new mechanical line, the technology tests and quality improvement have been done. The four castings in a mould, exhaust tablets and chill process ofEA111 crank casting were improved; furthermore, the volume and lining materials ofnodularization ladle, mechanical ladle were improved; in addition, the molten iron composition and alloy content were improved, then the mechanical performance and quality of crank were improved. As a result, the rejection rate of EA111 crankshaft reduced from 20% to 2%, External machining rejection rate reduced from 3% to 0.3%. The quality and yield of EA 111 crank meet Volkswagen＇s requirements.