Quality System
Level 3 File
QT
YGB-KPSNC-QT226-2013
(/)
Technical Feasibility
Analysis of Cylinder Head
Compilation：
Audit：
Countersignature：
Approved by：
2012-12-5 Release
2012-12-5 implementation
Kolbenschmidt Pierburg Shanghai Nonferrous
Components Co.,Ltd
I.
Product Technical Requirements Analysis
1. Product basic information
1.1 Part Number
1.2 Product Materials
1.3 Process Method
1.4 Mold Type
1.5 Product Weight
1.6 Delivered State
1.7 Product 3D Image
2. Material Properties
2.1 Material Grades
Determine the material grades according to customer requirements
(Reference to our company < Technical Conditions of Casting Aluminum/Zinc
Alloy YJ142009>)
2.2 Chemical Composition
Chemical composition can be adjusted appropriately according to customer
requirements
2.3 Mechanical Properties
Tensile Strength
Rm (MPa)
Yield Strength
Rp (MPa)
Elongation
A(%)
Brinell Hardness
(HBW)
2
3. Heat treatment
T5 - State of artificial aging after cooling during the high temperature molding
process
T6 - State of artificial aging after solution heat treatment
T7 – State of overaging after solution heat treatment
4. Cleanness
Cleanliness must meet customer requirements (SGM is on the basis of GMW
16037, SVW is on the basis of PV 3347)
5. Porosity
Whole porosity requirements
Porosity requirements in important area
Pore size requirements
6. DAS
Inspection position and value of the DAS is according to customer drawings
Inspection methods (SVW is on the basis of TL115/PV1112, SGM is on the basis of
GMN 7152)
7. Leak Test
Use compressed air — — Test pressure (Bar or KPa) — — Max leakage
(Ncm3/min or cc)
Water Jacket leak test
Oil galleries leak test
Ports / combustion chamber leak test
2
8. Tolerance
8.1 Casting unlabeled tolerance
Core, intake, exhaust, external mold, combustion chamber
8.2 Shape tolerance (profile tolerance) (mm)
External mold, oil gallery, water jacket, combustion chamber, intake, exhaust
8.3 Surface Roughness (Ra or Rz)
Combustion chamber, intake, exhaust
3
II.
Product Design Analysis
1. Wall Thickness Analysis
1.1 For cylinder head, general wall thickness is over 4 mm, but there must be
sufficient wall thickness between the respective cavities
1.2 General wall thickness between the intake and water jacket, oil gallery is
4-4.5mm, the minimum shall not be less than 3.5mm
1.3 General wall thickness between the exhaust and water jacket, oil gallery is
4-4.5mm, the minimum shall not be less than 3.5mm
1.4 General wall thickness between the water jacket and oil gallery is 6-6.5mm, the
minimum shall not be less than 4mm
1.5 General wall thickness between the water jacket and combustion chamber is
9-10mm, the minimum shall not be less than 5mm (Wall thickness between top
of the combustion chamber and water jacket shall not be less than 9mm)
2. Draft Analysis
2.1 External mold (suggest draft angle: 3º- 5º)
Including bottom face, intake face, exhaust face, front face and rear face
2.2 Core box (suggest draft angle: 3º)
3. Chamfer Analysis
3.1 Shape (suggest chamfer: ≥1.5º)
4
Including bottom face, intake face, exhaust face, front face and rear face
3.2 Internal core (suggest chamfer: ≥1.5º)
Including intake core, exhaust core, water jacket core, oil gallery core and riser
core
4. Shape Analysis
Giving amendment suggestions on defects due to the shape during casting
process
5
III.
Casting Simulation Analysis
1. Initial simulation
1.1 Determine casting system and mold structure
Including top gating , bottom gating and side gating
1.2 Setting process parameters
1.3 Analysis Result
1) Filling
Filling simulation output:
— Liquid metal flow process in the cavity
— Temperature change and heat transfer of each
element (liquid metal, mold and core) during the
filling process
— Liquid metal velocity change during the filling
process
— Cold shut, misrun, sand washing, gas, slag
inclusion and other defect during the filling
process
2) Solidification
Solidification simulation output:
— Metal solidification mode and feeding channel
— Solid time, temperature gradient and cooling rate in casting
— The key feeding position in casting
— Thermal load of mold, core and casting
— Cooling curve at any point in casting or mold
6
3) Heat treatment
Heat treatment simulation output:
— Mechanical properties
— DAS
— Stress change
— Deformation conditions
4) Criterion
Main criterion: Porosity, solid time, hot spot and so on. Among them, porosity is
the main criterion.
By studying these criterions, we can predict the position and size of the casting
defects accurately to provide a reliable basis for our modification proposal
2. Modified simulation
2.1 Modify the process proposal
2.2 Simulation again
2.3 Result analysis
1) Filling
2) Solidification
3) Heat treatment
4) Criterion
By studying these criterions, we can decide whether modify the proposal again
or not
7
Appendix:
Cylinder Head Technical Feasibility Analysis Check List
Part name:
No
customer:
Project
I
Product Technical Requirements Analysis
1
Product basic information
1.1
Part Number
1.2
Product Materials
1.3
Process Method
1.4
Mold Type
1.5
Product Weight
1.6
Delivered State
1.7
Product 3D Image
2
Finish
Material Properties
2.1
Material Grades
2.2
Chemical Composition
2.3
Mechanical Properties
Tensile Strength
Yield Strength
Elongation
Brinell Hardness
3
Heat treatment
4
Cleanness
5
Porosity
6
DAS
7
Leak test
8
8
8.1
Tolerance
Casting unlabeled tolerance
No
Project
8.2
Shape tolerance (profile tolerance)
8.3
Surface Roughness
II
Product Design Analysis
1
Wall thickness analysis
2
Draft analysis
3
Chamfer analysis
4
Shape analysis
III
1
Finish
Casting simulation analysis
Initial simulation
1.1
Filling
1.2
Solidification
1.3
Heat treatment
Mechanical properties
DAS
Stress change
Deformation
1.4
2
Criterion
Modified simulation
2.1
Filling
2.2
Solidification
2.3
Heat treatment
Mechanical properties
DAS
Stress change
Deformation
9
2.4
Criterion
10