发动机十字头铸造工艺设计优化

Casting Process Design Optimization of Engine Cross Head

利用铸造仿真模拟软件Flow-3D对发动机连接活塞与连杆的十字头的铸造工艺进行仿真模拟,完善了铸造工艺设计,优化工艺方案。结果表明,铸件主体两侧圆柱部分和突出部分,远离浇注系统一侧的卷气倾向大,出现气孔的概率较大。铸件表面缩凹、最后凝固部分将出现严重缩孔等缺陷。为了满足铸件的补缩以及排气需要,设置出气孔来防止气孔的产生,加大冒口尺寸以强化补缩等措施。对改进的工艺进行了砂型铸造试铸,发动机十字头铸件的缺陷基本消失。仿真设计有利于优化铸造工艺,提高质量。

The foundry simulation software Flow-3D was used to simulate the casting process of the cross head of connecting the piston and the connecting rod of the engine, casting process design was improved and the process plan was optimized. The results show that the cylinder part and the protruding part on both sides of the casting have a large tendency of air entrapment far away from the side of the casting pouring system, and the probability of air porosity is high tendency. Severe shrinkage cavity will appear on the surface of the casting and the final solidification. Therefore, in order to meet the needs of casting shrinkage and exhaust, air vents are set up to prevent the generation of air voids, and the size of the riser is increased to strengthen the retraction. The improved process was tested by sand casting, the defects of engine cross-head casting has been eliminated. Simulation design is beneficial to optimize casting process and improve quality.