具有复杂轮面的铝合金轮毂低压铸造工艺优化

Optimization of Low Pressure Die Casting Process for Alloy Wheels with Complex Wheel Faces

以某具有复杂轮面的铝合金轮毂为研究对象,运用ProCAST软件对铸件的充型、凝固过程进行模拟,以预测气孔、缩孔、缩松等缺陷的发生部位,并分析出现原因,从而进行工艺优化。结果表明,当降低初始升液速度至65mm/s时,铸件浇口附近的气孔缺陷减少。通过调整边模水冷系统水流速度至0.75m/s,并在轮辐两侧设立补缩通道,减小轮辐与轮辋连接处的热节面积,缺陷基本消除。使用优化方案对铸件进行试制,所得铸件无明显缺陷,力学性能优良,满足标准要求。

The ProCAST software was used to simulate the filling and solidification process of alloy wheels with complex wheel faces,and occurrence of the defects such as porosity,shrinkage porosity and shrinkage cavity was predicted and the origination of defects was analyzed.The simulated results reveal that when the initial lift velocity of metal liquid is reduced to 65 mm/s,porosity defects near the casting gate are relieved obviously.In addition,by adjusting the water flow velocity of the side mold water cooling system to 0.75 m/s and establishing the feeding channel on both sides of the spokes,the area of hot spot at the connection between the spoke and the rim is reduced and the defects are eliminated.The optimization scheme was adopted for producing trial-wheel.The results reveal that wheel surface exhibits clear with good mechanical properties and absence of significant defects,meeting the standard requirements.