Research And Application Of 468 Exhaust Manifold On DISA Production Line

Exhaust manifold is an important part of the automobile engines. It works in bad conditions and in working time, its temperature can reach 500℃due to the heat from the exhaust gas. With a thickness of pipe wall of 3mm, the exhaust manifold is a thin-wall part, so a high material quality is requested. In addition, the position and the function of the exhaust manifold in the engine makes it be of complex structure. The material of 468 exhaust manifold developed by DA company is Q450. The technology of Spheroidization is dealt with by Injection feeding technology. DISA upright molding line is used for molding. The using injection feeding Spheroidization technology and Uptight molding line is a leading card in our country, so the research of this production technology has an important engineering significance and theoretical and scientific value.This text concerns mainly the study of design and manufacturing of mold tooling and control of production process and analysis and solution of defects of 468 exhaust manifold casting. In order to design the mold tooling, analysis of structure and technology of 468 exhaust manifold castings is carried out and design of 468 exhaust manifold castings tooling is performed using I-DEAS software, including choice of casting location in the mold and of parting joint, design of pouting system and core structure etc. Production and demonstration of designed and manufactured tooling is also been performed.Through control and optimization of Injection feeding Spheroidization technology of 468 exhaust manifold, the casting spheroidization and inoculation decay problem is solved and the casting quality conformity is stabilized over 90%; at the same time, the wire consumption is reduced of 30%, so spheroidization cost decreases greatly and as a result, considerable economic benefice is brought to the factory.Analysis is also carried out to defects of 468 exhaust manifold casting occurred in production such as shrinkage and sand hole, inclusion and brittleness, and corresponding corrective measures are taken, so casting production reaches batch production condition.