82 Technical Not e s / J SAE Reriew 15 (1994) 73-86

1~- 2C r 20F
- , . - 01-
=
i / - \ i
..... j21
. SleeHngwhee ! a.g!e ~ - ~
: Yawveloclty / \ / "
~ F~gtmaat~on syslem
~Approximate equalion
lime (see)
Fig. 5. Actual vehicle test result (70 km/ h random pylon slalom).
5. Conclusions
From the preceding examination on simulation, it is
clarified that the time series pattern inputs of steering
angles and using the approximate equation based on a
2-degree-of-freedom linear vehicle mathematical model
are effective.
From the test performed for actual vehicles running
on a dry asphalt road, it is also evident that the system
can provide good estimation and noise reduction capa-
bility under conditions with an unknown velocity and
unknown random steering inputs.
The future task is mainly to examine whether or not
the present system can be further applicable to various
possible conditions, such as changes of actual road
surface or running conditions induced by acceleration
or deceleration of vehicles.
References
[1] Funabashi, K., On the Capabilities of Neural Networks, IEICE
Technical Report on MBE88-52 (1988).
Devel opment of light weight cylinder block
Hi sashi Kaj i kawa ,,a, Shouji Nomur a a, Hi r oaki Yasuda b, Makot o Mi har a b
Powertrain Production Engineering Department, Mazda Motor Corp., 3-1, Shinchi Fuchu-cho, Akigun, Hiroshima, 730-91 Japan
9 Powertrain Engineering Department, Mazda Motor Corp., 3-1, Shinchi Fuchu-cho, Akigun, Hiroshima, 730-91 Japan
(Received 31 August 1993)
I. Introduction
Weight reduction of a cylinder block (C/ B) im-
proves the vehicle power to weight ratio and lowers the
fuel consumption. Therefore, manufacture of C/ B' s
with thinner walls has been widely adopted.
However, this method has led to other problems
such as stiffness reduction due to thin walls. Therefore,
we studied material changes of C/ B with liner which
would offset this loss in stiffness and permit significant
weight reduction.
* Corresponding author.
2. Development goals
By adding magnesium, the graphite in cast iron is
spheroidized, resulting in improved mechanical proper-
ties including Young's modulus and tensile strength.
Therefore, we decided to use nodular graphite cast
iron (ductile cast iron, or DCI) instead of conventional
gray cast iron (FC) to get higher stiffness and strength.
Table 1 shows that DCI has superior mechanical prop-
erties compared to FC.
3. Properties of ductile cast iron C/ B (DCI C/ B)
3.1. Functional properties of DCI C/ B
DCI offers the advantages of high stiffness and
strength, offset by a lower damping ratio than FC
SSDI 0389- 4304( 93 ) E0012- 4 JSAE9430121
Technical Notes/JSAE Review 15 (1994) 73-86 83
Table 1
Mechanical properties of FC and DCI
Young's modulus Tensile strength
FC 122 GPa 255-305 MPa
DCI 171 GPa 440 MPa
(ratio) (1.4) (1.6)
Table 2
Result of FEM analysis
Weight reduction Resonance frequency (Hz)
rate (%) 1st torsion 1st bending
FC C/ B - 387 859
DCI C/ B 12.3 434 922
(1/8). To determine the vibration properties resulting
from using DCI for C/ B, it was necessary to evaluate
an identical C/ B manufactured from FC. Figure 1
shows the comparison between DCI C/ B and FC
C/ B; both the first-order torsional and bending reso-
nance frequencies are about 1.2 times higher than
those of the FC C/ B. Thus the stiffness (El) of C/ B is
increased by (1.2) 2 times with DCI.
Prior to the test, higher vibration amplitudes were a
cause for concern. However, due to the increase in
stiffness and resonant frequency coupled with an im-
provement in structural damping, it was found that the
vibration levels were decreased for the critical regions
of the frequency band.
Accordingly it was assumed that while maintaining
the higher stiffness and resonance frequencies, light
weight DCI C/ B' s with low vibration levels are feasi-
ble.
3.2. Possibility of weight reduction by FEM analysis
Following the C/ B testing, weight reduction poten-
tial from the use of DCI was investigated. Table 2
shows the results. It was found that with DCI, despite a
12% C/ B weight reduction achieved by thinning, the
resonant frequencies were slightly higher than with FC.
Thus it can be assumed that a weight reduction of
a~
0)
F i r s t t 0 1 H o n m o d e
2 0 d B 5 8 7 H ~ / l l l ~ " j 4 6 3 H ~ . , F i r s t 8 s ~ ~ z A - - . - ;n d in 9998, m o
/ / "x~ I
- " '
" x / /
/
FC C/ B \ /
DCI C/B ~ /
v
0 200 400 600 800 1000
F r e q u e n c y ( Hz )
Fig. 1. Relation between inertance level and frequency.
more than 12% is possible without an increase in
vibration.
It was also found that a 25% reduction in wall
thickness (from 4 mm to 3 mm) was required to achieve
it.
4. Production problems
DCI was used for C/ B with thinner walls. However
production problems such as elephant skin (a type of
misrun) and shrinkage defects occurred. These prob-
lems and their solutions are described below.
4.1. Elephant skin
Elephant skin occurred in the upper portion of DCI
C/ B. The mechanism of the elephant skin formation
was investigated by thermal analysis, as shown in Fig.
2. The following facts were established:
(a) Considerable temperature drop was observed
during the filling of the the mold with molten cast iron.
(b) Elephant skin occurred in the regions where
molten cast iron temperature drops to 1440 K (eutectic
solidification temperature of equilibrium diagram (1);
Fe- C- Si (2.5%).
From this result, we believe that elephant skin is
attributed to
(1) Beginning of the eutectic solidification accompa-
nied by falling temperature.
(2) Abrupt viscosity increase accompanied by begin-
ning of the eutectic solidification.
It was therefore assumed that, if the temperature of
molten cast iron is kept above 1440 K during the mold
fill, elephant skin would not occur.
To achieve this, gating to the involved portion of the
mold was enlarged to improve the flow of the melt.
Subsequent tests proved the effectiveness of this action
in maintaining the temperature of the upper portion of
C/ B above 1440 K. In this case elephant skin was
eliminated.
4.2. Shrinkage cavities
Massy solidification (DCI's solidification type) tends
to generate shrinkage cavities in DCI versus FC. How-
ever, part geometry influences this problem. An ideally
84
~J
e-,
09
Technical Notes/JSAE Retiew 15 (1994) 7_7-86
a
t
f
t
tions, however, adopting a suitable shape to prevent
shrinkage cavities is often very difficult.
Therefore, improvement of solidification balance by
setting chills was investigated by solidification analysis
and the following found;
Solidification balance was improved (directional so-
lidification was attained) by chill's cooling capacity and,
in this case, areas where shrinkage cavities usually
occurred were defect free.
4.3. Microstructure of DCI C / B
The microstructure of DCI C/ B as investigated by a
microscope, and it was confirmed that DCI C/ B' s
exhibit sound spheroidized graphite (graphite nodular-
ity is over 70%) in the ferri t i c/ pearl i t i c matrix.
In summary, it was confirmed that production of
DCI C/ B without defects, such as elephant skin,
shrinkage cavities, and anomalous structure is possible.
Fig. 2. (a) Temperature distribution of C/ B; (b) Portion of elephant
skin.
designed DCI C/ B had no shrinkage cavities. Solidifi-
cation analysis was made to investigate this geometrical
factor and the following were observed:
(a) C/ B which have shrinkage cavities had areas
where shrinkage cavities coald be generat ed (tempera-
ture gradient is under 0.5 K/ c m) in the same area.
(b) C/ B which have no shrinkage cavities also have
no areas where shrinkage cavities could be generated.
To depress shrinkage cavities, the C/ B should be
designed with suitable geometry. Due to design limita-
5. Co n c l u s i o n
DC1 is a suitable cast iron for weight reduction
because of its high Young' s modulus. And when it is
used instead of FC for C/ B, weight reduction of over
12% is possible.
Although there had been some problems to make
light weight DCI C/ B, satisfactory production methods
were developed.
Re f e r e n c e s
[1] Akechi, et al., Nodular Graphite Cast Iron Basic and Application
(in Japanese), Agune P. 13 (1983).