基于MAGMAsoft的铝合金变速箱壳体压铸工艺优化

Die Casting Process Optimization of Aluminum Alloy Gearbox Housing Based on MAGMAsoft

以某汽车铝合金变速箱为例,根据其结构特征,确定分型面,运用三维建模软件UG进行初始浇注系统的设计。基于MAGMAsoft软件进行充填和凝固过程的数值模拟,介绍了铝合金变速箱壳体在压铸成型过程中参数的设计过程。采取最优压铸工艺,设计模具、压铸生产,得到符合图纸技术要求的产品。针对变速箱壳体在组装后台架及路试中出现的泄漏问题,通过数值模拟及工业CT分析,找到原因,通过在泄漏的相应位置处增加高压点冷的方式,使问题得到解决,后期台架及路试试验未出现泄漏,从而验证了本优化的正确。为变速器壳体的压铸生产及产品缺陷分析解决提供了一有效方法,提高了产品质量并缩短了生产周期。

Taking an aluminum alloy gearbox of an automobile as an example,according to its structural characteristics,the parting surface is determined,and the initial gating system is designed by using 3D modeling software UG.Based on the MAG-MAsoft software,the numerical simulation of filling and solidification process is carried out,and the parameter design process of aluminum alloy gearbox shell in the die casting process is discussed.Adopt the optimal die-casting process,design the mold,carry on the die-casting production,get the product that meets the technical requirements of the drawing.In view of the leakage prob-lem of the gearbox shell in the bench test and road test after assembly,the reason was found through numerical simulation and in-dustrial CT analysis,and the problem was solved by adding high pressure point cooling at the corresponding position of the leak-age,and no leakage occurred in the bench test and road test in the later stage,thus verifying the correctness of the optimization.It provides an effective method for the die-casting production of transmission housing and the analysis and solution of product de-fects,which improves the product quality and shortens the production cycle.