基于数值模拟的铝活塞铸造过程优化

Optimization of Aluminum Piston Casting Process Based on Numerical Simulation

为了降低铝合金活塞铸造缺陷,基于MAGMA软件对不同活塞铸造模具结构和铸造工艺进行模拟分析,结合DOE设计确定了最优的模具和铸造工艺方案,并进行了试验验证。结果表明,当采用将内浇道向下增加45°斜角,增大保温冒口尺寸且对铸造模具销芯进行60 s冷却的组合方案时,有效减少了活塞铸造缩松缺陷,解决了活塞销座厚大部位由于缩松导致的废品率高的问题,且减少了反复修模、试模的成本,提高了产品品质。

In order to reduce casting defects in aluminum alloy piston, the die structure and casting process of different pistons were analyzed by the MAGMA software, and optimal die and process scheme were determined and verified combined with the DOE design. The results indicate that the shrinkage porosities in piston are effectively reduced through the combination scheme of increasing the inner gate angle by 45 degrees downward, increasing the size of the insultnant riser and cooling the pin core of the casting mold for 60 s, which solves high scrap rate caused by shrinkage in the thick piston pin seat area, and saves the trial-manufacture and production cost of repeated mold repairing and test, thus improving the casting quality of products.