薄壁AlSi10MnMg结构件压铸工艺数值模拟与优化

Numerical Simulation and Optimization of Die-Casting Processes for Thin-wall AlSi10MnMg Structural Parts

以某薄壁AlSi10MnMg铝合金结构件为研究对象,利用正交试验法,设计多因素多水平正交试验寻求优化工艺参数组合。利用Pro/Engineer对浇注系统和铸件整体进行三维建模。在Flow-3D软件导入几何模型,对不同参数水平组合下的铸件充型状态进行数值模拟,得到充型结束后的卷气模型示意图。利用Photoshop对输出图片中铸件的卷气含量比例进行计算,对单指标的试验结果进行直观分析,得出最优参数,从而完成对压铸工艺的优化。使用优化的工艺进行生产验证,微观组织观察和X射线检测结果显示铸件质量良好。

This study takes a thin-wall AlSi10MnMg structural part as the research object, an orthogonal experiment with multi factors and levels was designed for studying the optimal die-casting process parameters. Three-dimensional gating system and casting parts were modeled by Pro-E software. Simulation software Flow- 3D was employed to import the geometrical model and to simulate the filling state of the mold cavity under different levels of parameter combinations. The air entrapment volume at the end of the filling stage was measured to calculate the air entrapment ratio of the casting in the output picture by software Photoshop. The experimental results of the single output index were analyzed intuitively and the optimal parameters were obtained. The optimization results were verified by actual production, and the experimental results showed that the components produced by optimized parameters have a satisfying quality.