汽车离合器压盘铸造数值模拟及工艺优化

Numerical Simulation and Technology Optimization of Automotive Clutch Pressure Plate

在DISA线生产汽车离合器压盘铸件时,铸件出现了严重的缩孔缺陷,导致了产品报废。运用铸造模拟软件ProCAST对铸件充型和凝固过程进行模拟,分析缺陷产生的原因。根据模拟结果优化原始工艺,将原底注式浇注工艺改为阶梯式浇注,缩短补缩浇道的长度、加大补缩浇道截面和冒口的尺寸,同时在冒口颈附近设置补贴。对改进后的工艺再进行模拟,发现中间层浇道提前进浇,出现了严重的冲刷和裹气。对工艺再次进行优化,将中间层浇道向上倾斜并减小其截面,同时增大底层浇道的截面;将浇注温度降低至1350℃。采用二次改进后的工艺生产的铸件缩孔缺陷消除,铸件质量完好,成品率大幅度提升。

The serious shrinkage defect was formed in automotive clutch pressure plate produced in DISA casting production line, which caused the whole products were rejected. The filling and solidification process of the pressure plate was simulated by casting simulation software ProCAST to analyze reasons of the existing defects in the casting, and the original process was optimized according to the simulation results. The original process using the bottom gating system was improved for step gating system, the feeding runner length was shorten, and the size of runner and riser were increased; at the same time, pad was set near the riser neck. Through simulation of the optimized process,it was found that the middle runner was poured early, there were serious erosion and gas entrapment. The process was optimized again by inclining the middle runner, reducing the cross section, increasing the cross section of the lower layer and adjusting the pouring temperature to 1350℃. After two times improvement, the casting shrinkage hole defect was eliminated, and the quality of the casting was greatly improved.