3. Foundry equipment

The equipment used in the automotive foundry industry must be fast-paced, highly efficient, and highly reliable for continuous operation. Due to the high quality requirements of car castings, these casting equipment must be of high precision. Equipment required for the automotive foundry industry. For China's caster foundry industry, it is undoubtedly a market with high profits, but most of the foundry equipment manufacturers have weak technical strength, lack of technical development capabilities, and each fights themselves, without the advantage of combining production----research. The strength of the force is thin, so I have to look at many foreign casting equipment manufacturers, and robbed a large number of equipment orders in China's automobile foundry industry. The young Chinese automobile foundry industry, despite the shortage of funds, had to import some key equipment at a high price, otherwise it could not produce the automobile castings needed for the car. This dilemma must be reversed. Appropriate practices can be adopted, such as Sino-foreign joint ventures, cooperative methods, or domestic production, study, and research, and joint development with users, as well as the import of key components (such as servos, hydraulic components, electronics, electronic control components, etc.). These are all ways to accelerate the improvement of China's casting machine industry, and also solve the demand for high-level, high-reliability and reasonably priced casting equipment in China's automobile foundry industry. At this stage, close cooperation between the manufacturer and the user is important, both in the design process, in the manufacturing process, in the installation and commissioning process, and in the use and maintenance process. This is conducive to the shortcomings of some casting equipment manufacturers in China who do not understand the casting process.

The improvement of the starting rate of equipment in the automobile foundry industry for a large number of flowing water production is also an important issue faced by automobile foundry manufacturers. In addition to strengthening personnel training and equipment management, the supply of equipment spare parts and the management of spare parts are also important aspects. The fuzzy expert system of foreign equipment maintenance spare parts can be used as a reference for the decision management of spare parts and the computer simulation system for equipment maintenance training.

4, quality management

Although China's automobile foundry manufacturers have passed the ISO9000 quality argument of the previous period, they also attach importance to people (employees), machines (equipment, molds), materials (original and auxiliary materials), laws (process, operation), and rings in daily management. (Working environment, process process), testing (detection, inspection) six major factors affecting quality, but have not yet grasped the effective and stable operation of the ISO9000 quality assurance system, and have not yet included the above six major influencing factors into the numerical control state. In particular, the consistency of the quality of the original and auxiliary materials, the stability of the equipment, the state of the mold, and the effectiveness of the quality control of the production process are very different. As far as the development, design and process development of new products can be carried out, the ability of quality assurance is considered at the same time, so that the possible casting defects can be eliminated to the maximum before the production is put into production. We should stand on the user's point of view to review the quality of the castings, so that the users are satisfied (not just the satisfaction of the company) and operate according to the ISO9000 quality assurance system. This is a passport to enter the international market. If our castings are to be supplied to Volkswagen AG in Germany, we must pass the VDA6.1 certification required by the company. To supply to a large American automobile company, we must pass the QS9000 certification they require. The quality assurance system of German and American automobile companies regards the quality control of raw materials into the factory as a key link and considers it to be a prerequisite for stable casting quality.

In the production process, quality control can not be limited to sampling, or single-process control, to strengthen online real-time control, conditional process to implement closed-loop control. For example, the cupola should be controlled by the three-dimensional network curve of air volume and coke consumption according to the preset molten iron temperature and melting rate. This is a necessary measure to reduce fluctuations in components such as C and SI. Otherwise, the cupola will in fact become an "uncontrollable cupola". Even if the raw materials are ideal, the fluctuations of components such as C and SI will not be controlled to a minimum. Advanced quality control and control instruments, such as X-ray fluorescence spectrometer for raw and auxiliary material quality inspection, image analyzer for casting alloy, computer expert system, artificial neural network control technology such as neural network and fuzzy control, can be applied to cupola Quality inspection control such as smelting process and molding sand preparation process. The quality control of finished castings not only reduces the scrap rate, but more importantly improves the internal quality control (ie material properties), surface quality, lumen cleanliness and dimensional accuracy, which is the user's greatest concern. Digital data storage should be used for all kinds of data, parameters, photos, images, tables, etc. of quality management, which not only greatly saves photos and paper, but also facilitates the analysis and sharing of information. It is necessary to minimize the inventory of raw and auxiliary materials, sand core inventory, and casting inventory, which not only reduces capital occupation, accelerates capital turnover, but also facilitates quality tracking management, which helps analysis and judgment of quality problems, improves quality and reduces Cost is significant. In short, we must make the entire enterprise and the entire production process in a controlled (not out of control) state, and incorporate them into our comprehensive quality assurance system for stable and reliable operation. This will ensure that the system will initially produce castings that are satisfactory to the user.

5, technology development

The automobile foundry industry should use the parallel engineering work method to change the traditional serial and sequential working methods, and work with the automotive product development department to intervene from the product development stage and integrate the casting process requirements into the overall concept of product design. At the same time, within the foundry enterprise, the personnel of various categories are also brainstormed to form the working mode of TEAM (team) to improve work efficiency. In terms of CAE, we have introduced MAGMA and PRO-CAST software in the foundry industry. Our foundry workers have also developed some casting software, which can use CAD 2D and 3D data of the product, using the above simulation process of casting process and solidification process. Simulation, metallographic organization, composition segregation and material performance simulation, simulation of velocity field, concentration field, temperature field, phase field, stress field, strain field, etc. This will allow us to optimize the process plan by CAE means before the formal determination of the casting process.

On the basis of CAE optimization, we can use the advanced RP rapid formation technology to carry out trial production of new product castings. That is, the one-dimensional data of CAD/CAE is used as the control data of the three-dimensional modeling of the computer, and the material is stacked layer by layer by the bonding, sintering or sintering to form a prototype of the casting or to form a prototype of the desired shape of the casting. The former can be used to cast a casting sample by means of lost wax casting, etc., the latter can be directly used as a mold for self-hardening sand to form a core shape and cast a casting. Powdered laser sintering (SLS) can also be used to sinter the sand and directly cast the casting. CAD/CAE three-dimensional data can also be input into CNC machine tools, and CAM processing can be performed with machinable plastics, and core boxes and patterns required for trial production of castings can be obtained for trial production of small batch castings. In short, the combination of CAD/CAE and RP makes the process optimization and casting trial break through the lengthy, inaccurate and unsatisfactory modes of traditional 2D drawings and wood mold trials, which greatly shortens the development cycle, especially the cylinder block, The shortened development time of complex castings such as cylinder heads, gearbox housings, intake and exhaust manifolds, etc., is of great significance for shortening the development cycle of the entire engine and the vehicle and placing it on the market as soon as possible. After the completion of the above-mentioned trial production, with the finalization of the whole machine and the new product of the whole vehicle, in the formal production preparation process, the CAD data of the metal mold can be continuously used to carry out the computer-aided manufacturing of the metal mold--CAM. Thanks to the CAE simulation optimization and the trial basis of RP, the commissioning cycle of the formal molds processed by CAM is also significantly accelerated. In the CAF simulation and RP trial production, the casting process plan and related process parameters have been optimized, so that after the formal mold debugging and production of CAM, there will be few major quality problems, and it is no longer necessary to tackle the problem in daily production. Casting scrap rate is very low, which makes the dimensional accuracy, intrinsic quality and surface quality of castings quickly meet the requirements of users. The CAE simulation and simulation described above can also be used for process optimization, defect prevention and quality improvement of cast-in-place castings, which is a traditional method for solving some "unpredictable" casting defects by trial and error methods of experience and skill. It is a major scientific breakthrough. CAE is not only a simulation of the forming process of casting, but also a simulation of the casting production process, such as computer simulation of the smelting process of the cupola furnace, simulation of the sand filling and compaction process of the air blasting, simulation simulation of the die casting process, etc., so that the casting science The technical level is improved faster.

6, factory technical transformation

In the planned economy period, in many cases, the technological transformation of the factory is aimed at expanding the production capacity. After entering the market economy period, we must invest in the technical transformation of the original factory. We must not only increase the production capacity, but also the materials that can be produced. The more types of castings that can be produced, the better. Through the adoption of new technologies, new processes, new materials and new equipment, through the process reengineering, the original factory will continuously improve the quality assurance capability, further save energy, save resources, and improve the level of clean production and environmental protection. In this way, we can continuously reduce costs, continuously improve the “environmental impression” of the society, and help attract more talents to engage in the automobile foundry industry, further promote the technological progress of the automobile foundry industry, and thus promote the improvement of economic efficiency. We should not only focus on the harmless treatment of the end in reducing environmental pollution, but more importantly, we must start from the input side - starting from material saving, energy saving, and from design to production, we must consider the optimal use of resources. And environmental protection, so that the development of our car foundry industry and the protection of the ring. Enterprises must not only pass the ISO9000 quality system certification, but also pass the ISO14000 environmental protection certification, so as to continuously improve the company's efficiency and social benefits.

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