镁合金壳型件压铸数值模拟及缺陷分析

Filling and solidification simulation of shell part of die-casting magnesium alloy and some defects analysis

为避免镁合金压铸壳型件产生缺陷,利用有限差分模拟软件Flow-3D对镁合金壳型压铸件的充型及凝固过程进行多组正交试验,找出最佳的工艺参数。模拟结果表明:最佳压铸工艺参数为压射速度6m/s、模具温度220℃和浇注温度700℃。在最佳的模具温度及浇注温度下,得到不同的压射速度对后续凝固过程的影响。通过模拟结果分析,可以有效地预测在充型和凝固过程中可能出现的缺陷、形成位置及其形成原因,以使在实际生产中采用相应的措施避免产生缺陷,优化铸造过程。

In order to carried out for filling avoid the defects of magnesium alloy shell part, the orthogonal experiments are and solidification process of magnesium alloy shell part by using the software of finite difference simulation software Flow-3D to determine the optimized parameters. The simulation results show that the optimized parameters are including the injection velocity with 6 m/s, mold tem- perature with 220 ℃, and pouring temperature with 700℃. The influences of different injection ve- locity on solidification are compared under the same optimized parameters of mold temperature and pouring temperature. According to simulation results, the types of defects, forming position and me- chanics are predicted. Eventually the corresponding methods are adopted to avoid these defects, and the casting process is optimized.