CAE充型模拟改善缸体铸件渣气孔缺陷

CAE Filling Simulation to Improve the Defect of Slag Porosity in Cylinder Casting

针对某商用车发动机缸体铸件机冷器室部位的渣气孔缺陷,运用CAE模拟技术,发现浇注系统存在铁液量不均匀、铁液未按顺序充型、头股铁液汇集无法排走、形成的密闭空间空气无法排走、温度场不均匀、机冷器面温度降低过快等问题。采取在直浇道底部增加一层底注内浇道的措施来改进浇注系统的设计,并通过CAE模拟分析和批量生产验证,有效改善了渣气孔缺陷,使机冷器的渣气孔缺陷由12%降低至了0.1%以下,取得了良好的经济效益。

Aiming at the defects of slag porosity in the cooler chamber of a commercial vehicle engine cylinder casting,CAE simulation technology was used to find that there were some problems in the pouring system,such as uneven amount of molten iron at the gate,non sequential filling of molten iron,inability to discharge the first strand of molten iron,inability to discharge the air in the enclosed space formed,uneven temperature field,and rapid temperature reduction on the cooler surface.The measure of adding a layer of inner runner at the bottom of the straight runner is adopted to improve the design of the pouring system,and through CAE simulation analysis and batch production verification,the slag porosity defect is effectively improved,which is reduced from 12%to less than 0.1%,and good economic benefits are obtained.