基于田口方法的Cu-45Ag合金金属型铸造过程仿真及工艺优化

Optimization of Permanent Mold Casting Processes for Shrinkage Porosity Reduction in Cu-45Ag Alloy by Simulation and Taguchi Method

通过田口方法 (DOE)、数值模拟和浇注试验相结合,研究了浇注温度、铸型温度和涂料厚度对宏观缩孔体积率的影响,并对金属型铸造Cu-Ag合金工艺进行了优化。通过实际浇注试验,对模拟结果的可靠性以及田口方法分析得到的置信区间进行验证,获得了最优工艺方案:浇注温度为1 100℃、铸型温度为200℃、涂料厚度为1.5mm。

The shrinkage porosity in Cu-Ag binary alloy fabricated by permanent mold casting was analyzed by the Design of Experiment（DOE）based on Taguchi method,numerical simulation and casting experiment.The effects of processing parameters,such as pouring temperature,mold temperature and coating thickness,were analyzed on quality of shrinkage porosity ratio of Cu-Ag alloy.The numerical experiments with different processes were designed by Taguchi method and the simulated results were analyzed based on the signal-to-noise ratio（S/N）and analysis of variance（ANOVA）.The influence of various process parameters on shrinkage porosity was described,and optimization of processing parameters was also proposed.Then the validity of the method and its confidence interval were confirmed by the verification test.The results indicate that the optimized process parameters are presented as follow：pouring temperature of 1 100℃,mold temperature of 200℃and the coating thickness of 1.5 mm.