铝合金机油泵盖压铸模浇注及溢流系统仿真优化设计

Simulation and Optimization Design of Pouring and Overflow System for Die Casting Mold of Aluminum Alloy Oil Pump Cover

为了高效、高质量生产某汽车发动机机油泵盖,针对泵盖零件特征并基于压铸理论和经验设计了3种理论上可行的浇注与排溢系统方案,然后利用ProCAST软件模拟铸件的充型及凝固过程。充型过程模拟发现铸件顶部易产生卷气,因此提出在此处增设一个溢流槽的优化方案。铸件凝固仿真发现,消除横浇道内侧溢流槽以及缩短内浇道长度,对铸件的缩松、缩孔分布无影响,还可改善横浇道内侧铸件部位的散热、减少金属液流动能量损失。方案三的浇注与排溢系统降低了卷气,试模铸件经X光探伤表明重要位置无缩孔,金相分析显示铸件各部位组织致密,晶粒度等级为4,显微硬度大于HV85,符合产品要求。

In order to produce an automobile engine oil pump cover efficiently and with high quality, three kinds of theoretically feasible pouring and overflow systems were designed according to the characteristics of the pump cover parts and based on the die-casting theory and experience. Then ProCAST software was used to simulate the filling and solidification process of the casting. It was found that the top of the casting was prone to air entrainment during mold filling process simulation, so an optimized scheme was proposed to add an overflow tank here. Casting solidification simulation showed that eliminating the overflow groove inside the sprue and shortening the length of the inner sprue had no effects on the distribution of shrinkage cavity and porosity of the casting, and could also improve the heat dissipation of the casting inside the sprue and reduce the energy loss of metal liquid flow. The casting and overflow system of scheme 3 reduced the air entrainment.X-ray flaw detection showed that there were no shrinkages in the important positions of the casting.Metallographic analysis showed that the structure of each part of the casting was compact, the grain size was 4, and the microhardness was more than HV 85, which met the requirements of the product. The die design method optimized based on die casting theory and experience combined with ProCAST simulation analysis is convenient and efficient, which provides a useful reference for die design of the die casting.