大直径铝合金活塞的模具设计和铸造工艺优化

Mould Design and Casting Process Optimization of Large Diameter Al Alloy Piston

在原铸造工艺基础上,利用德国MAGMA铸造凝固模拟分析软件,对大直径铝活塞毛坯铸件的浇注、凝固过程进行数值模拟,预测了铸件产生铸造缺陷的可能部位。根据模拟结果,对模具结构和原有铸造工艺进行改进和优化。改进后模拟效果良好,经生产验证,铸件质量明显提高,达到大幅度缩短活塞的试制周期,节约试制成本,提高产品质量的目的。

The pouring and solidification process of large diameter AI alloy piston casting are simulated with MAGMA software on the basis of the original casting process, which indicates the potential position of casting defect. According to the simulated result, the mould structure and casting process can be improved and optimized. The simulation results with improved mould are well. The casting quality is improved obviously by production verification. Therefore, the targets of greatly shortening trial-production period, reducing the trial-production costs, and improving the product quality were realized.