Research On The CAD/CAE/CAM Technology Of Iron Mould Coated Sand Casting Mold For Crankshaft

To meet the market of engine in terms of performance, energy saving and emissions, the high power, low fuel consumption, emissions and explosion pressure naturally aspirated engine, matching the domestic well-known commercial vehicle production enterprises, has broad market prospects. Along with the cut of the price of the the current auto industry and the increasing of the iron and steel, such as the rising of the energy prices, it is imperative to explore "casting instead of forging","iron instead of steel" of the crankshaft production process requirements. Advanced iron mould coated sand casting process can well meet the requirements of crankshaft blank manufacturing, but it’s lack of scientific theoretical basis and precision process design for most of the iron mould coated sand casting enterprises at present. So it is hard to guarantee the production process of casting quality, and its low production efficiency are also seriously restricts the development of enterprise. Therefore, to design, analysis and optimization of mold design and processing of the iron mould coated sand casting process equipment, CNC automatic programming is of great significance for the development of crankshaft blank casting technology and the auto industry.Aiming at some problems of this technology, this paper deals with the research and improvement as follows:In this paper, a diesel engine factory CY4105ductile iron rolling nitride crankshaft as the research object,compared with traditional humid sand mold casting process, it’s of great superiority of iron mould coated sand casting process to the crankshaft. According to the technological characteristics of iron mould coated sand casting and production experience, it completed the design of the casting, coated sand, Shoot sand agencies, Shakeout mechanism, and pouring system. Then completed the upper and lower template of the iron mould coated sand and the casting of the assembly equipment design, etc., and generated the engineering drawing of the products.According to the symmetrical iron mould structure of the four cylinder crankshaft a, choosed a typical crank parts, its matching iron mould coated sand and also its coating as a geometric model, analysis was carried out on the pouring temperature based on the ANSYS finite element. Mapped the temperature-time history curve of the critical point, preliminarily determined the time to open the iron mould, after the trial production, adjusted the final time to out of according to the actual test temperature. It can make the casting heat transfer more evenly during solidification, preventing casting defects such as shrinkage porosity. Further optimized the design of the iron mould coated sand casting process, and provide scientific theory basis for equipment.In this paper, using UG software, analyzed the crankshaft processing technology of iron mould coated sand casting mould,choosed the appropriate processing methods, to generate the CNC machining program G code of virtual machining, and validated tool motion trajectory. Using the DNC software CIMCO, transmited data to the machine tool production.By means of the analysis of the common casting defects and its prevention measures, the article briefly introduced the quality and technology of iron mould coated sand casting mould of the crankshaft.Through to the quality testing of the crankshaft blank casting, it’s stable of the mechanical properties.It reduced the product rejection rate caused by casting defects, and truly achieved the "casting instead of forging","iron instead of steel" of the crankshaft production process requirements.Above all, the research of this paper is helpful to improve the quality of the crankshaft blank casting and reduce the production cost, speed up the mold development cycle of new products, improve the market competitiveness of new products. It has significant technical, economic and social benefits.The research results can provide theoretical basis and practice guidance for the crankshaft blank casting production, so that it can be applied in other similar products during the process of casting molding.