铝合金U形外环框架砂型铸造工艺设计及仿真模拟

Design and Simulation of Sand Casting Process for An U-shaped Aluminum Alloy Outer-Ring Framework

研究了一种铝合金U形外环框架的铸造工艺方法。针对该铸件外形复杂、壁厚较薄、内腔结构复杂的特点,根据单件小批量生产的要求,在工艺中采用两箱造型工艺。该工艺降低了造型高度,简化了模样制作,方便了内腔型芯的制作和安放。提前制作同质铝棒,铸入铸件本体,既消除了热节,又对型芯起到了支撑作用。在设计浇注系统时,采用了片状直浇道,保证了足够的流速和流量,也保证了液态金属平稳流动,有效地防止了由紊流带来的氧化、夹渣和卷气。分散的内浇道避免了局部过热,改善了热平衡。通过对铸件的仿真模拟,分析了工艺的可行性,确定了整套完整、合理的工艺方案。

A kind of casting process for an u-shaped aluminum alloy outer-ring framework was studied.Aiming at its complicated contour,thin wall thickness and complex cavity,according to single piece or small batch production requirement,two-split-molding process was used,the molding height reduced,the fabrication of the mould was simplified and it’s convenient for the manufacture and placement of inner cavity core by the process.Aluminum rods made of the same material were prepared previously and were cast into this framework,which not only eliminated thermal center but also supported the major mould cores.When the gating system was designed,flake-shaped sprues were used to ensure not only adequate flow rate and flow but also steady flow of molten metal,which prevented the oxidation,slag and wrapped gas caused by turbulent flow.Dispersed gates were adopted to avoid local overheating and improve heat balance.Through the simulation of castings,the feasibility of the process was analyzed,and a complete and reasonable process plan was determined.