一种能提升重型柴油机铝活塞毛坯铸造成品率的模具改进技术.docx

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一种能提升重型柴油机铝活塞毛坯铸造成品率的模具改进技术

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朱荣华

摘要：重型柴油机铝活塞同普通汽油机铝活塞相比有许多不同，重型柴油机铝活塞的重量是普通汽油机的5～8倍，为了提高耐磨性能，铸造时需要在柴油机铝活塞毛坯中镶嵌合金耐磨圈。重型柴油机气缸中燃烧产生的热量非常高，需要对活塞进行强制冷却，为此目的还需要在柴油机铝活塞毛坯内部开设内冷油道。重型柴油机铝活塞铸造存在合金耐磨圈镶嵌位置左右偏移、上下移位，与铝合金结合面脱落。活塞盐芯铸造过程中存在安放位置上浮、开裂，与铝合金结合面飞边严重，铸造成品率低等问题。针对重型柴油机铝活塞难以做到高率、高成品率铸造的问题，深入研究铸造工艺与模具结构关系，多次鑄造实验和探索，改进外模外形结构、加工工艺，改变芯模、盐芯销组件结构。获得了一种能大幅度提升重型柴油机铝活塞毛坯铸造成品率的模具改进技术。

Abstract：Therearemanydifferencesbetweenheavydutydieselenginealuminumpistonandcommongasolineenginealuminumpiston.Theweightofheavydutydieselenginealuminumpistonis5～8timesofthatofcommongasolineengine.Inordertoimprovethewearresistance，itisnecessarytoinsertalloywearringinaluminumpistonblankofdieselengineduringcasting.Theheatproducedbycombustioninthecylinderofheavydutydieselengineisveryhigh，sothepistonneedstobeforcedcooled.Forthispurpose，itisalsonecessarytosetupaninternalcoolingoilchannelinsidethealuminumpistonblankofthedieselengine.Inheavydutydieselenginealuminumpistoncasting，theinlayingpositionofalloywearringisshiftedfromlefttoright，upanddown，andthejointsurfacewithaluminumalloyfallsoff.Therearesomeproblemsinthecastingprocessofpistonsaltcore，suchasfloatingandcracking，seriousflashonthejointsurfacewithaluminumalloy，andlowcastingyield.Inviewoftheproblemthatitisdifficulttocastaluminumpistonwithhighyieldandhighyieldforheavydutydieselengine，therelationshipbetweencastingprocessanddiestructureisstudiedindepth，castingexperimentsandexplorationarecarriedoutformanytimestoimprovetheexternalmoldstructureandprocessingtechnology，andtochangethecoremoldandsaltcorepinassemblystructure.Adieimprovementtechnologywhichcangreatlyimprovethecastingyieldofheavydutydieselenginealuminumpistonblankwasobtained.

关键词：重型柴油机;铝活塞;铸造质量;成品率;技术改进

Keywords：heavydutydieselengi