高速动车组铝合金齿轮箱铸造工艺产业化升级

The Industrial Upgrading of Foundry Technology for Aluminum Alloy Castings Used in High-speed Rail Gear Box

介绍了国内外高速动车组齿轮箱箱体的技术要求和铸造工艺现状,开发了齿轮箱箱体的金属型低压铸造工艺。对试制中出现的气孔、缩孔缩松及针孔等缺陷进行分析,并通过MAGMAsoft软件进行箱体铸造工艺模拟分析和优化,采取有效措施成功地解决了气孔、缩孔缩松及针孔缺陷,开发出质量稳定、可靠的金属型低压铸造齿轮箱。根据金属型低压铸造工艺特点,自主设计、建设了一条先进高效的生产线,满足了批量生产应用需求,实现了高速齿轮箱铸造工艺产业化升级换代。

The technical requirements and casting process of high speed EMU gear box all over the world are introduced. The low pressure die casting process of high speed EMU gear box was obtained. The casting defects found during development of high speed EMU gear box such as blowholes, the shrinkage and dispersed shrinkage, as well as pinholes were analyzed. The foundry technology of gear box castings was analyzed and optimized by solidification simulation software MAGMAsoft.Then some useful measures were taken to solve these casting defects successfully. According to the requirements of low-pressure metal mold casting process, an advanced and efficient production line has been independently designed and found to meet the needs of mass production.This realizes the industrial upgrade of the foundry technology for the high speed EMU gear box.