Research On Application Of Shell Casting Technology Of Nodular Castiron Crankshaft Of S1100 Diesel Engine

This paper makes experimental study on technology and equipment of melting, molding, coremaking and pouring which are applied on manufacturing of iron shot shell molding crankshaft of S1100 diesel engine by using Chinese-made equipments and materials. Emphatically it makes tests and study on applicable technology of chemical composition selection of nodular cast iron, feeding mechanism, gating system design, casting blank design, core-making design and iron shot filling molding etc. so that the iron shot shell molding technology can be applied and popularized in production.Through tests and examination in production practice, following points should be paid attention to in manufacturing of crankshaft by using iron shot shell molding technology:In the case of causing no graphite floatation, carbon equivalent should be increased as much as possible.On the basis of ensuring rigidity and strength of shell mold, the compactedness of shell mold filling iron shot should be improved as far as possible.To strengthen liquid feeding and decrease liquid contraction.To select rationally jolting force and jolting time for filling iron shot.To increase pouring rate can effectively prevent casting from subsurface blowhole.It is an important measure to eliminate blowhole with exhausting a great deal of gas during pouring smoothly .With full consideration of the homogeneity of the pattern shell and convenience of pattern drawing in manufacturing of pattern shell, reject ratio can be reduced greatly Grain fineness of iron shot must be controlled to strengthen chilling of filling iron shot to mold and keep the pattern shell with certain strength and rigidity.Multipoint clamping or follow fixture should be adopted in adhesion of pattern shell.To reduce machining, according to technological experiment, the machining allowance for single side of inside of ring plate can be reduced to 0.5-0.7mm.The results show that with strictly controlled chemical composition of nodular cast iron, rational feeder head gating, exact right technology and design, rational shell making and molding technology, manufacturing crankshaft with iron shot shell molding technology using Chinese-made equipments and materials has notable advantages, such as improved casting quality, high precision of repeatability, low investment, low production cost and high productivity, which is particularly suitable for manufacturing of crankshaft with no more than four cylinders.