制动器卡钳体倾斜铸造过程数值模拟及其优化设计

Numerical Simulation and Design Optimization of Tilt Casting Process for Car Caliper

根据实际生产中倾斜铸造工艺特点,采用有限元软件ProCAST对制动器卡钳体充型和凝固过程进行数值模拟。通过对充型过程的结果分析,研究了铝液流场和温度场的分布特点;通过对凝固过程的结果分析,研究了铝液固相率的变化规律,并预测了缺陷位置。结果表明,在充型过程中铝液流动平稳,无冷隔浇不足等缺陷;在凝固过程中存在缩孔、缩松缺陷,主要集中在臂端、底部厚大部位及中心通孔附近。最后提出工艺优化方案并进行模拟,改善了卡钳体缩孔缩松的分布情况,并运用到实际生产进行验证,提高了铸件成品率。

The filling process and solidification process of brake caliper were simulated by ProCAST of the FEM software based on the actual production process. According to the analysis of the results of the filling process, the distribution of flow field of aluminum liquid and temperature field was researched. Meanwhile, by analyzing the results of the solidification process, the change rule of the solid fraction of aluminum liquid was researched, at the same time, the defects were predicted. The results show that the aluminum liquid flow is smooth without cold shut and short run during filling process, while shrinkage cavity gatheres in the thick place of the arms and the bottom and the center hole place. Finally, a process optimization scheme was proposed and simulated to improve the distribution of shrinkage cavity in the key parts. Through actual production verification, the casting yield in production is improved.