基于有限元的压铸模寿命预测和工艺优化

Service Life Prediction and Process Optimization of Die Casting Die Based on Finite Element Method

使用有限元数值模拟软件研究了压铸工艺参数对压铸模热疲劳性能的影响。首先通过ProCAST软件模拟了压铸循环热平衡状态下的温度场,然后将温度场热载荷作为ABAQUS软件的初始条件进行加载,并通过ABAQUS软件得到压铸循环过程中的热应力变化和热疲劳寿命结果。结果表明,由模拟得到的模具热疲劳最短寿命区域与压铸模进行疲劳失效试验获得的热疲劳裂纹产生区域相符合,验证了模拟结果的准确性。此外,设计了以热疲劳寿命为试验目标的压铸工艺参数的正交模拟试验,优化得出了合理的压铸工艺参数。

The influence of die-casting process parameters on the thermal fatigue performance of die-casting die was analyzed by means of numerical simulation. Firstly, the temperature field under the thermal equilibrium state of die-casting cycle was calculated by the ProCAST software, and then the thermal load of temperature field was loaded as the initial condition of ABAQUS software. The thermal stress change and thermal fatigue life during die casting cycle were obtained by ABAQUS software. The calculated minimum thermal fatigue life area of the die was compared with the thermal fatigue crack generation area obtained from the fatigue failure test of the die-casting die, and the accuracy of the simulated results was verified. Based on this, the orthogonal test of die-casting process parameters with thermal fatigue life as the test objective was designed, and the optimized die-casting process parameters were presented.