I. Manufacturing process:
a. Mould preparation: according to the design requirements, prepare the casting pattern and mould.
b. Casting preparation: Prepare the casting equipment, including the centrifugal casting machine, furnace, and other auxiliary equipment.
c. Material Melting: Heat the selected casting material (usually aluminum alloy or cast iron) to a molten state.
d. Centrifugal casting: The melted material is added to the centrifugal casting machine, and the centrifugal force is used to cast the melted material into cylindrical castings.
e. Cooling and curing: After completion of casting, the castings are cooled and cured to obtain the required properties and dimensional accuracy.
f. Machining: According to the design requirements, the castings are subjected to subsequent machining, such as turning and grinding.
II．Material selection:
Commonly used materials for centrifugal cast cylinder liners include aluminum alloys and cast iron. Aluminum alloy has better thermal conductivity and lightweight characteristics and is suitable for high-performance engines, while cast iron has better wear resistance and is suitable for conventional engines. The choice of material needs to be reasonably considered based on factors such as the use environment, engine power, and expected performance.
III. Processing requirements:
a. Dimensional accuracy: centrifugal cast cylinder liner requires high dimensional accuracy, which needs to meet the design requirements of diameter, height, roundness, and surface finish.
b. Surface treatment: The inner and outer surfaces of the cast cylinder liner need to be finely treated to ensure good sealing and lubrication.
c. Strength and hardness: According to the working conditions and requirements of the engine, the cast cylinder liner needs to have enough strength and hardness to withstand the impact and wear of high pressure and high-temperature environments.
d. Quality control: Strict quality control is required during the manufacturing process, including chemical composition analysis, non-destructive testing, and dimensional measurement of the castings to ensure product quality.
Cylinder liner will sometimes be deformed in use, centrifugal casting cylinder liner deformation is generally due to the following reasons:
I. Improper selection of materials: The quality and composition of casting materials have a great impact on the performance of casting parts. If the selected material is not strong enough, or there are smelting quality problems, may lead to casting cylinder liner deformation.
II. Improper control of the casting process: All aspects of centrifugal casting, such as pouring temperature, pouring speed, injection pressure, cooling time, etc., need to be strictly controlled. If these parameters are not set properly, it may cause deformation of the cylinder liner.
III. Uneven pressure: In the process of centrifugal casting, liquid metal enters the cavity through the pouring port under the action of centrifugal force. If the pouring is not uniform, or the sealing performance is not good, it will lead to uneven pressure inside the cylinder liner, which in turn leads to deformation.
IV. Improper cooling treatment: centrifugal casting parts need to be cooled to achieve the desired physical properties. If the cooling rate is too fast or uneven, or the temperature of the cooling medium is not suitable, it may lead to the deformation of the cylinder liner.
V. Unreasonable design: The design of the cylinder liner should consider factors such as force and thermal expansion. If the design parameters are unreasonable, such as too thin wall thickness, uneven structure, etc., it will increase the risk of cylinder liner deformation.
Note: The above are some of the possible causes of deformation of centrifugal casting cylinder liner, the specific circumstances also need to be based on the specific casting process and the actual situation to judge.
Generally, the ways to solve the deformation of centrifugal casting cylinder liner include:
I. Optimize mould design: ensure the stability and uniform cooling effect of the mould to avoid deformation problems caused by uneven temperature and uneven cooling speed.
II. Controlling the cooling speed: ensuring uniform temperature and cooling speed during the cooling process, avoiding deformation caused by too fast or too slow cooling in some areas.
III. Appropriate treatment of internal or external stress: Take reasonable process measures, such as heat treatment, hot pressing, etc., to release or balance the stress of the metal to avoid deformation.
IV. Optimization of sealing: In the design and processing of cylinder liners, focus on the optimization of sealing to ensure a good fit between the cylinder liner and other components to reduce the possibility of deformation.
Welong is a company specializing in casting and forging. Since its inception, we have adhered to the policy of "honesty, professionalism", and the courage to participate in the healthy competition in the market, our centrifugal casting cylinder liner has a good reputation. We adhere to the principle of service first, customer first, so that Welong has won the trust of many customers and established a good corporate image.
