铝合金凸轮轴盖压铸模浇注系统设计

Gating System Design of a Die Casting Die for Aluminum Alloy Camshaft Cap

为开发某凸轮轴盖压铸模,在理论设计的浇注系统基础上,利用ProCAST软件对铸件充型凝固过程进行模拟分析。研究发现,采用6横浇道方案因多流汇合易引起卷气和缩孔缺陷,而采用5横浇道方案可降低压铸件卷气和内部孔隙率;通过凝固、缩孔和缩松仿真预测了孔隙的位置及体积,据此提出去除一个溢流槽的优化方案。浇注系统优化后可明显缩短凝固时间,铸件X光探伤和关键位置切面未发现宏观缩孔。

ProCAST software was used to simulate the mold filling and solidification process based on a theoretically designed gating system for obtaining a reasonable camshaft cap die-casting mold.The results show that the 6-runner scheme can result in multi-flow confluence,causing gas entrapment and shrinkage defects,while a 5-runner scheme can reduce the gas and internal porosity in die castings.The locations and volume of the pores were predicted by simulation of solidification,shrinkage holes(porosities),and then an optimized scheme removing an overflow groove was proposed,which could significantly shorten the solidification time.X-ray inspection and cutting surface of the key position of the die-cast castings show that absence of shrinkage hole in the product can be observed.The efficiency of mold design can be improved by die-casting simulation,and the production efficiency as well as product quality can be enhanced though pouring system optimization.