基于MAGMA的铝合金连接器压铸工艺优化

Optimization of Connector Part Structure and Die Casting Process Based on the MAGMASOFT

基于MAGMASOFT软件的温度场、热节分布等计算结果,采用减小壁厚、设置加强筋等措施,优化了冷却水连接器铸件结构,使原本采用砂型铸造的铸铁件改为了适于压铸的铝合金件。通过对连接器的压铸成形工艺如浇注、冷却、排溢等进行计算,确定了合理的工艺方案。生产结果表明,采用优化后的铸件结构及成形工艺方案,铸件内部、外观品质以及气密性测试均符合技术要求。

Casting internal defects such as shrinkage porosity,entrapped gas are mainly decided by the part structure and forming process.The solidification temperature field and hot spot distribution in connector were analyzed by the MAGMASOFT.Through reducing the wall thickness and adding the ribs,above mentioned defects in the optimized casting structure can be eliminated.Aluminum alloy was adopted to conduct die casting instead of cast iron to sand casting by optimizing connector structure.Based on calculating pouring,cooling and exhausting system of die casting process,rational die casting scheme was designed.The results reveal that the casting＇s internal and external quality as well as tightness test meet the technology requirement.