基于数值模拟的铝合金舱体差压铸造工艺优化

Optimization of Counter-pressure Casting Process for Aluminum Alloy Cabin Body Based on Numerical Simulation

利用数值模拟对某铝合金舱体的差压铸造过程进行了分析。结果表明,采用传统的垂直缝隙式浇注系统无法实现平稳的逐层充填,充型过程中金属液飞溅和液面翻滚现象严重。基于模拟结果和理论分析,改进了原设计的浇注和补缩系统结构。通过采用环形缝隙式浇注系统有效改善了充型状态,在增加工艺筋尺寸的同时配合使用冷铁与顶冒口,获得了较为合理的凝固顺序,缩短了凝固保压时间,提高了生产效率。

The numerical simulation was applied to analyze the filling and solidification process of Al alloy cabin body in counter-pressure casting process.The results indicate that it is difficult to achieve a smooth and layer-by-layer filling pattern by using traditional vertical slot-type pouring system as a result of the splash and rollover of liquid metal.Consequently,the pouring and feeding system was improved based on the simulation and theoretical analysis.The adoption of ring-shaped slot pouring system can improve effectively the filling quality,and a reasonable solidification sequence can be obtained by enlarging the ribs and utilizing the chill blocks combined with top riser.Furthermore,the pressure-holding time was shortened to increase the productivity based on simulation results.