大功率柴油机缸体的铸造工艺设计及质量提升

Casting Process Design and Quality Improvement of HighpowerDiesel Engine Cylinder Block

针对柴油机缸体生产过程中超过40%铸件发生渗漏问题,分析得到渗漏位置为U型水道芯及挺杆芯之间。根据铸件的结构和技术要求,通过金相检测和数值模拟分析,确定了铸造缺陷为渣气孔缺陷,并提出通过减少粘结剂用量、使用混合型涂料或者石墨基涂料代替碱性涂料、调整熔炼时炉料配比等工艺优化措施,改善后的铸件渗漏率降低到2%以下,有效提升了缸体产品质量。

More than 40%of castings of diesel engine cylinder block leaked during production.The analysis showed that the leakage position was between the U-shaped channel core and the tappet core.The structure and technical requirements of castings were analyzed.The casting defect was determined to be slag porosity defect through metallographic detection and numerical simulation analysis.Process optimization measures such as reducing binder dosage,replacing basic coating with mixed coating or graphite-based coating,adjusting the ratio of charge in smelting were proposed.The improved casting leakage rate was reduced to less than 2%,effectively improving the quality of cylinder block products.