الصفحة الرئيسية / دراسات الحالة / حالات الصب بالقالب / تصنيع غطاء صمام المحرك عن طريق عملية الصب بالقالب

تصنيع غطاء صمام المحرك عن طريق عملية الصب بالقالب

عملية التصنيع	خدمة صب القوالب
مواد القطع	AlSi10Mg
نوع القالب	قالب القالب المصبوب
صناعة التطبيقات	السيارات
معالجة السطح	طلاء المسحوق
التسامح (الدقة)	± 0.1 مم

الملاحظات:

لدينا اتفاقيات سرية قبل التسويق مع جميع عملائنا. جميع الحالات التي تراها تم التواصل فيها مع عملائنا. لقد قمنا بفسيفساء بعض المعلومات الحساسة. جميع الصور مأخوذة من التصوير الداخلي لشركة FirstMold، شكرًا لدعمكم وتعاونكم~

التفاصيل
المتطلبات
الأسئلة الشائعة

An automotive customer from Mexico approached First Mold to manufacture a series of engine valve covers.

Requirements For Engine Valve Covers Manufacturing

المواد: Lightweight yet strong aluminum alloy (AlSi10Mg) to reduce vehicle weight and improve fuel efficiency.
تشطيب السطح: A smooth, corrosion-resistant surface with a tolerance of ±0.1mm.
حجم الإنتاج: 50,000 units per year.
كفاءة التكلفة: Competitive pricing while maintaining high quality.

Engine Valve Covers Manufacturing Process

Design Review and Tooling Development

Upon receiving the design from this customer, First Mold’s engineering team conducted a thorough design review to ensure manufacturability. The team identified potential issues such as thin wall sections and complex geometries, which could lead to casting defects. A customized die was designed, incorporating features like optimized gating and venting systems to enhance material flow and reduce porosity.

Die Casting Process

Die Preparation: The mold was preheated to 200°C to prevent thermal shock and ensure uniform material flow.
الصب: Molten aluminum alloy was injected into the تجويف القالب at a pressure of 1,500 bar
Cooling and Ejection: The part was cooled and solidified within 30 seconds, followed by automatic ejection from the die.

Finishing and Quality Control

After casting, the valve covers underwent a series of finishing processes, including trimming, shot blasting, and machining. A high-quality powder coating was applied to enhance corrosion resistance and aesthetics.

First Mold employed rigorous تدابير مراقبة الجودة, including dimensional inspection using coordinate measuring machines (CMM) and X-ray inspection to detect internal defects.

Challenges and Solutions In Engine Valve Cover Manufacturing

Porosity Issues

Issue: During the initial production phase, some valve covers exhibited porosity, a common die-casting defect characterized by the presence of small voids or gas pockets within the metal. This defect compromised the structural integrity of the parts.

الحل: The engineering team implemented a vacuum-assisted die-casting technique, which significantly reduced air entrapment and ensured a dense, defect-free casting.

واربج

Issue: The complex design led to minor warping during cooling, affecting the part’s flatness. Warpage is a common issue in die casting, caused by uneven cooling rates or stresses within the material.

الحل: By optimizing the cooling rate and redesigning the cooling channels within the die, First Mold achieved uniform cooling, minimizing warpage and ensuring dimensional accuracy.

النتائج

First Mold successfully manufactured 9000 units of high-quality engine valve covers for this customer, we received high praise from them.

تفاوتات الأبعاد

التسامح: ±0.1mm.
التسطيح: Deviation ≤0.05mm across sealing surfaces.

السلامة الهيكلية

الخواص الميكانيكية: Must meet or exceed specified tensile strength and hardness requirements.
Critical Areas: Free of defects in bolt holes and sealing surfaces.

Visual Inspection

المظهر التجميلي: Uniform surface finish, consistent coloring, and absence of discoloration or blemishes.

Q1. What are the common defects in die-casting engine valve covers, and how can they be prevented?

Common defects include porosity, warpage, cold shuts, and surface roughness. These can be prevented by using vacuum-assisted casting, proper die temperature control, optimized cooling channels, and high-quality materials. Rigorous quality control checks are also essential.

Q2. How do you handle the machining and finishing of engine valve covers?

After casting, valve covers undergo trimming to remove excess material, followed by precision machining to meet tight dimensional tolerances. Finishing processes such as shot blasting and powder coating are applied to enhance surface finish and corrosion resistance.

Q3. Can you manufacture other engine components besides valve covers?

Yes, we specialize in manufacturing a variety of engine components, including cylinder heads, engine blocks, intake manifolds, and engine bracket parts. Our expertise in die casting and machining allows us to produce high-quality parts for various engine applications.

Q4. How do you ensure the sealing surface of the engine valve cover is flat and defect-free?

We use precision machining and flatness testing equipment to ensure that the sealing surface meets stringent flatness requirements. This process prevents oil leaks and ensures a proper seal with the engine head.

Q5. What are the typical lead times for producing engine valve covers?

Lead times can vary based on the complexity and quantity of the order. Standard lead times range from 4 to 6 weeks, with expedited options available for urgent projects.

Q6. How do you manage thermal expansion issues in aluminum valve covers?

Aluminum expands with temperature changes, so we design valve covers with proper allowances for thermal expansion. This includes ensuring sufficient clearance for mating parts and using flexible sealing materials to accommodate expansion and contraction.

Q7. What testing and quality control measures are in place for engine valve covers?

Our quality control measures include dimensional inspections, X-ray inspections for internal defects, surface roughness testing, and pressure testing to ensure the covers are free of leaks and meet all specifications.

Q8. Can you provide custom branding or logos on the engine valve covers?

Yes, we can incorporate custom branding or logos into the die-cast design. This can be done through engraving, embossing, or other methods during the casting process.

Q9. How do you handle high-volume production orders for engine valve covers?

We have scalable manufacturing processes that allow us to efficiently manage high-volume production orders. Our facility is equipped with multiple die-casting machines, automated handling systems, and skilled personnel to ensure consistent quality and timely delivery.