基于ProCAST的柴油机活塞铸造工艺模拟及优化

Simulation and Optimization of Casting Process for Diesel Engine Piston Based on ProCAST

为解决某船用柴油机活塞在铸造过程中出现的缩孔、缩松缺陷问题,基于三维建模软件以及铸造仿真模拟软件,以QT700活塞铸件为研究对象,运用UG绘制其三维模型图,利用ProCAST软件模拟活塞铸件的铸造过程并预测缩孔、缩松缺陷可能出现的区域。根据活塞铸件的结构特点设计了轴向引入和径向引入两种底注式浇注系统。研究表明:径向引入底注式浇注系统相比于轴向引入底注式浇注系统在减少铸件缩孔、缩松缺陷上更有优势。进一步研究浇注温度、充型时间以及铸型温度等对铸件缩孔、缩松率的影响规律,并通过正交试验获得最佳的工艺参数组合。最后,在铸造缺陷产生部位增加补缩冒口,有效地消除了铸造过程中的缺陷。

In order to solve the problems of shrinkage and dispersed shrinkage defects in the casting process of a marine diesel engine piston,based on the three-dimensional modeling software and casting simulation software,taking QT700 piston casting as the research object,the three-dimensional model diagram was drawn by UG,the casting process of the piston casting was simulated by ProCAST software,and the possible areas of the shrinkage and dispersed shrinkage defects were predicted.According to the structural characteristics of the piston castings,two kinds of bottom injection gating systems,axial introduction and radial introduction,were designed.The research results showed that the radial introduction bottom injection gating system had more advantages in reducing shrinkage and dispersed shrinkage defects than the axial introduction bottom injection gating system.The effects of pouring temperature,mold filling time and mold temperature on the shrinkage of castings were further studied,and the best combination of process parameters was obtained by orthogonal experiment.Finally,feeding riser was added at the position where casting defects occur,effectively eliminating defects in the casting process.