SiC_p/A356制动盘铸造成形工艺设计和缺陷预测

Casting Process Design and Defect Prediction of SiCp/A356 Brake Disc

SiCp/A356复合材料制动盘具有轻质低噪长寿命等突出优点,在城市轨道列车基础制动系统中具有广阔的应用前景。但SiCp/A356复合材料铸造性能较差,成形过程中极易形成气孔、缩孔缩松及裂纹缺陷。本文利用ProCAST凝固模拟软件对制动盘的金属型真空调压成形工艺进行仿真分析,基于流场、缩孔缩松、凝固时间及固相率等结果,确定了制动盘内部成形质量良好的浇注系统设计和浇注工艺参数,成形了内在质量完好的SiCp/A356制动盘。

SiCp/A356 composite brake discs have outstanding advantages such as light weight, low noise, long life, etc., and it has broad application prospects in the basic braking system of urban rail trains. However, the castability of SiCp/A356 composites materials are poor, and pores, shrinkage porosity and crack defects are easily formed in the forming process. The metal mold vacuum pressure regulating forming process of the brake disc was simulated and analyzed by using ProCAST solidification simulation software. The results show that based on the results of flow field, shrinkage cavity and porosity, solidification time and solid phase ratio, the design of casting system and casting process parameters with good forming quality inside the brake disc are determined, and SiCp/A356 brake disc with good internal quality is prepared.