ES8B2上盖压铸工艺设计及数值模拟

Numerical Simulation of Die Casting Process of ES8B2 Upper Cover

根据ES8B2上盖的结构特点,设计浇注系统和排溢系统,使用Flow-3D软件对铸件的工艺方案进行模拟。初始方案的模拟结果显示,浇注系统及其附近的区域温度较高,型腔的两端和溢流槽温度较低,并且型腔的两端产生了较多的卷气。对初始方案进行优化,改变横浇道的形状,调整溢流槽的位置和大小。对优化后方案模拟结果显示,温度分布为中间高、两端低,型腔两端出现更多卷气;对方案再次优化,增大内浇口的面积、溢流口的面积、溢流槽的体积和连接肋的截面积。模拟结果显示,型腔中的卷气明显下降,铸件气孔减少,缺陷降低。实际生产铸件表面光滑,缺陷较少,符合生产要求。

According to the structural characteristics of the ES8B2 upper cover,the feeding system and the overflow system were designed,and the casting process was simulated by Flow-3D software.The simulated results of the initial scheme reveal that the gating system and its adjacent areas have a higher temperature,however the temperature at both ends of the cavity and the overflowing slot was reduced.The volume fraction of entrained air was observed in the two ends of the cavity.The initial scheme was optimized by changing the shape of the horizontal channel and adjusting the position and size of the overflowing slots.The simulated results reveal that the temperature distribution is high in the middle,while the two ends are low,and more volume fraction of entrained air appears at both ends of the cavity,so the scheme was optimized again by increasing the area of the gate and the overflow port,the volume of the overflow slots and the cross-sectional area of the connecting ribs.The simulated results show that the volume fraction of entrained air in the cavity is reduced significantly,and the blowholes are reduced,so the defect is reduced in the casting.The surface of castings is smooth with fewer defects,meeting the requirements of production in actual production.