/ Aswnews/August 16, 2022 Guangzhou - On August 15, Shichuang Technology released the "White Paper on Integrated die casting Digital Technology", which systematically summarized the prospects and difficulties of the hot integrated die casting technology in automotive application in recent years, and elaborated how digital tools can be integrated die casting for universal benefit, so that enterprises can realize digital upgrade faster. Based on the current development status of integrated die casting and computer simulation technology, the white paper looks forward to the trend direction of intelligent manufacturing in the future, and accelerates domestic automobile enterprises to enter a new stage of industry.
This is the first time in the industry to describe the changes and challenges brought by integrated die casting to the automotive industry chain from the perspective of digital technology.
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The value of digital technology in integrated die casting < P > The lightweight demand of new energy vehicles is urgent, integrated die casting is the necessary means to achieve it, it will replace the previous mainstream stamping and welding process in the body design and assembly process on a large scale, achieve more than 10% weight reduction, become the weight of the automobile production link Want revolution. At the same time, integrated die casting can also help enterprises significantly reduce the time and labor cost required for the production of automobile parts, at least or even up to one tenth of the original, to achieve cost reduction and efficiency increase.
But at the present stage, the rapid popularization of integrated die casting also faces many difficulties. It not only challenges the existing equipment performance to the limit, but also overturns the traditional engineering experience in a series of links from production materials, design, process to quality control. Because the mold volume is expanded more than ten times, the metal liquid is more sensitive to temperature, vacuum absorption and other parameters than before. According to the traditional production mode, the mechanical characteristics are easy to meet the requirements, which is unacceptable in the high strength of the automobile structural parts.
Moreover, integrated die casting also eliminates the traditional space of multiple trials and errors. The biggest characteristics of integrated die casting are huge size, thin and uneven wall thickness, and complex shape. The required design complexity and calculation amount reach a new order of magnitude, and the production end should need more time to adapt. However, the pace of market demand for integrated die casting production has not slowed down, but continues to accelerate. So trying to find that balance by trial and error with just people and devices is expensive and out of step with market demand.
The white paper argues that digital technology will change from an auxiliary technology to a dominant factor in the face of integrated die casting, which has entered no man's land. With the continuous progress of computing scale, computer graphics, artificial intelligence and other technologies, digital technology can predict and optimize integrated die casting design solutions, help enterprises solve problems encountered in production, and even realize automatic intelligent design.
< p> In the production process of integrated die casting, digital technology can improve the success rate of production and the reliability of castings from structural design, process design, quality testing and other aspects.
One of the difficulties of integrated die casting is the die temperature system. If the large die does not reach the state of thermal balance, it will form a huge obstacle to the filling and forming of metal liquid. However, the traditional monitoring mechanism is not comprehensive enough in the first place. It can not cover all the factors such as thermal resistance and water road distribution of parting surface between different parts of the casting, so it is difficult to put forward an effective and comprehensive improvement scheme for the mold design. Moreover, even if the data is obtained, the temperature control system also lacks a real-time feedback adjustment mechanism, which can not adjust the temperature in time, aggravating the waste of materials and time.But after computer simulation, enterprises can not only carry out comprehensive simulation of the scheme before production, timely improve the process and design. In the production process, the simulation data and real-time temperature monitoring can also be combined to establish AI intelligent mold temperature control system, breaking the barrier of the previous detection system "each for itself", getting rid of the dependence on skilled technicians, and making the decision-making system automatic.
The difficulties of integrated die casting do not stop there. The traditional die casting is relatively not strict in the assessment of mechanical properties of each part, but in integrated die casting, the properties of different parts are generally different, which will have a great impact on the material, and it is difficult to use X-ray or manual detection of defects, making the correction more difficult. Casting defects that are difficult to find and solve not only have a great impact on the process debugging, assembly and subsequent service of casting, but also threaten the mass production. Through key technologies such as machine learning, the blind test accuracy of today's intelligent detection system can reach 95%. The algorithm can also be adjusted to get rid of the dependence on the past data set, so that the defect detection can quickly adapt to the new process material.In addition to the above cases, at present, digital technology has played an important role in the determination of thermodynamic parameters of alloy materials, the design and control of vacuum system and other links. In the actual production process, digital technology can also complete the demand calculation at the fastest speed through the mode of cloud computing and multitasking concurrency, which is the future trend of development. The importance of digital technology to intelligent manufacturing
At present, the industrial layout of integrated die casting has become more and more perfect, and is constantly improving. In the future, the work of die casting engineers will be gradually transferred to the computer. In order to break through data barriers and significantly improve efficiency, digital technologies required for integrated die casting will continue to broaden the field, and finally form data platform collaboration, forming a full-link, multi-scale intelligent production system in the whole industry.
For example, through the input of the final parameters and constraints of the casting, the optimal solution of the mold design can be automatically obtained, and the simulation results can also be seamlessly connected to the production link for intelligent control. In the final stage of quality inspection, the effect similar to the "black light factory" can also be achieved: unattended, zero missed inspection.
According to the white paper, in the future, the market demand of die casting industry will show the characteristics of small batch, flexibility and short product cycle. A complete digital manufacturing ecosystem not only enables the automobile industry to quickly adapt to the pace of production and realize industrial upgrading, but also enables small and medium-sized enterprises to maximize the release of productivity, make full use of their unique advantages, and not be restricted by resources.
< /p>Finally, digital technologies are reshaping the country's auto industry chain and redistributing production value, the white paper said. In the future, more manufacturing enterprises will take the initiative to embrace digital technology, and intelligent manufacturing will be systematic and normalized. At that time, industry pioneers who take the lead in adopting digital technologies will not only receive more dividends, but also lead the whole industry into a new round of manufacturing prosperity.
