The Study On The Key Technologies Of Epc And Mould Of Engine Block

Currently, the sand casting process is used to produce the automobile engine block in many domestic works. The development of using EPC process to produce the engine block is prevented by great technical difficulties. These technical difficulties are the key technologies of EPC. With the development of computer technology recently, the numerical simulation technology is applied in the casting process widely. Through numerical simulation software the position of casting defects can be predicted, and optimize the casting process parameters.In the paper, Unigraphics NX 4.0 as the 3D modeling software, the ProCAST software which is belong to a French company who is called ESI as numerical simulation software, the affect of different gating system on the cast iron which was produced by EPC was studied. The affect of different pouring temperature and vacuum degree on the filling of engine block which was produced by EPC process was analyzed. The defect of the engine block was predicted. Taking into account the EPC and the requirements of mould design, the mould of the engine block which was applied in EPC was designed. The foam of qualified was produced by the mould, and the quality of the casting was consistent with the manufacturers. According to this study, the results as following:①The basic difference between the EPC and the traditional casting process is that there is a certain air gap pressure in the interface of the mould and casting, the flow and filling of metal is hindered. The filling style of the liquid metal is the center spread type in the EPC process, and the filling is relatively stable.②Depending on the structure of the casting, to choose the right gating system is necessary. The filling styles of variety gating system about the iron casting had been simulated. When the gating system was the bottom-rain gating system, the air gap resistance was small, the filling speed was moderate, defects was less, and the filling was smooth.③In the paper, drawing the method of sand casting, the runner-element cross-sectional area of the gating system which was applied in EPC had been calculated by using the hydraulic formulas. A closed hollow sprue-open gating system was a good ratio of cross-sectional area when the runner was larger by 1.2~2.2 times.④The worth of the pouring temperature and the vacuum were different, the filling time was different to the engine block which was produced by EPC. The affect of several sets of different pouring temperature and vacuum to the filling style of EPC had been studied. When the worth of the pouring temperature was 1440, and the worth of the vacuum degree was -0.05, the filling was stable, and there were not such phenomenon as liquid metal stop.⑤The ProCAST software was used to simulate the engine block's solidification process of EPC, the vary of the temperature in the EPC process could be reflected, the defects were predicted, a reference was provided to the improvement process for the future, as the same time the cost was saved, and the efficiency was improved.⑥The Unigraphics NX 4.0 software was used to design the EPC mould of engine block, the integration and visualization from casting design to mould design were achieved, which was propitious to modify or design the models, the design's flexibility and efficiency were improved.