铝合金箱体低压铸造数值模拟及其优化设计

Numerical Simulation and Design Optimization of Low Pressure Casting Process for Aluminum Alloy Case

通过对铝合金箱体结构及低压铸造工艺特性的分析,合理设计浇注系统,并利用ProCAST软件对充型和凝固过程温度场进行数值模拟,发现充型过程流动平稳,温度场较为均匀,但在凝固过程中由于结构的复杂性,在厚壁及热节处出现缩松缺陷。在改进方案中,通过在铸件厚壁处设置冷铁和增大横浇道出口截面积等措施,缩短凝固时间,强化补缩通道,最终通过工业CT断层扫描检测,获得无铸造缺陷的高品质铸件。

It is reasonable to design gating system according to analysis of low pressure casting aluminum alloy case structure and characteristics.It is flown smoothly in the filling process with uniform temperature field distribution by using the ProCAST software,however,due to structure complexity,there exist a lot of shrinkage porosity defect in the thick wall and hot spot position during solidification process.In the optimized scheme,by setting cold iron at the thick wall of the case and increasing sectional area of the runner exit,solidification time was shortened and the feeding channel was enhanced.High quality aluminum alloy case without defects was produced by industrial CT tomography detection.