ES11ZD上盖压铸工艺设计及数值模拟优化

Numerical Simulation Optimization of Die Casting Process of ES11ZD Upper Cover

分析了ES11ZD上盖的结构,设计了初步的压铸工艺方案,并使用Flow-3D软件对初始方案进行数值模拟。铸件充型过程的温度场模拟分析表明,初始设计符合充填规律且温度分布合理;根据卷气分布情况,可知在细圆筒处易出现气孔。因此对初始方案增加溢流槽的体积,模拟结果显示卷气减少,但内浇口附近仍然有卷气。在内浇口与型腔的连接处添加倒圆角,减少了内浇口附近的卷气。根据优化工艺进行实际生产,铸件表面光滑、缺陷较少。

The structure of ES11ZD upper cover was analyzed to design the initial die casting process.Then Flow- 3Dsoftware was applied to simulate the initial scheme.The filling simulation reveals that filling process presents reasonable with the uniform temperature distribution.It is predicted that blow-hole can easily appear in the slender cylinder according to the distribution of entrainment gas.The initial scheme was improved by increasing the volume of overflow slots.The results show that the entrained air is decreased,however there still exists entrainment gas near the feeding gate.A chamfer was added at the connection between the feeding gate and the mold cavity in order to decrease the entrainment gas.Through using the optimized process design,the actual castings presents smooth surface with few defects.