一体式空心副车架快速试制工艺

Rapid Trial Production Process of Integrated Hollow Sub-Frame

对铝合金一体式空心副车架开展砂型反重力铸造研制工作。为缩短铸件研制周期,首先利用PROCAST软件对一体式空心副车架进行热分析,根据分析结果设计砂型反重力铸造工艺,进一步对铸件充型和凝固过程的流动场、温度场进行计算,并结合缩松和氧化物数值模拟结果判断铸件内部缺陷大小及位置,最终确定铸造工艺方案。在此基础上,采用3D喷墨打印技术快速制备砂型、砂芯并浇注,完成了一体式空心副车架的快速试制。对一体式副车架凝固过程进行了应力分析,并利用激光三维扫描对比铸件热处理前后的变形情况。结果显示,空心副车架铸件质量良好,力学性能较高。

Anti-gravity casting technology of aluminum alloy integrated hollow sub-frame was researched. To shorten the development cycle of castings, thermal analysis of integrated hollow sub-frame was carried out with PROCAST software firstly. Based on the analysis results, the anti-gravity sand mould casting process was designed, and then the flow field and temperature field during filling and solidification of castings were calculated. The size and location of internal defects in castings were judged with the help of simulation results of shrinkage and oxide inclusions. Finally the casting process was improved. On this basis, sand moulds and cores were rapidly prepared by 3D inkjet printing technology, and the rapid trial production of integrated hollow sub-frame was completed successfully. The internal stress of the solidification process was analyzed, and the dimensional changes of the castings before and after heat treatment were compared using threedimensional laser scanning technology. Results show that the quality and mechanical properties of sub-frame all meet the technical requirements.