铝合金缸盖倾转铸造数值模拟及优化研究

Numerical Simulation and Optimization of Tilting Casting Aluminum Alloy Cylinder Head

采用Magma软件对汽车用铝合金缸盖在倾转条件下的充型、凝固过程进行了数值模拟,通过对模拟结果进行分析,研究了倾转铸造过程中铝液充型速度、各部位卷气情况及凝固顺序与铸件中缺陷分布倾向的关系,并在实际生产中对模拟结果进行了验证。在后续优化工艺中,通过增大补缩冒口消除缩孔缺陷,将倾转角速度由匀速改为阶梯变速,大大降低了集成排气侧出现气孔缺陷的几率,使铸件合格率达到了96%。

Filling and solidification process of aluminum alloy cylinder head with titling casting process were simulated by the Magma software,and relationship of the distribution of casting defects with filling velocity,air entrapment and solidification sequence in titling casting process were analyzed.The results were validated in actual production.In the subsequent optimization process,the porosity defects in the castings were eliminated by enlarging the feed riser,and the risk of porosity defects on the integrated exhaust side was reduced greatly by changing the tilting angle velocity from uniform speed to ladder speed,and the qualified rate of the castings reached to 96%.