高铁制动系统用活塞铸件工艺开发

Development of Piston Casting Technology for High-speed Rail Braking System

高铁制动系统中的活塞,全身X射线探伤和MT/PT探伤,要求缺陷等级不超过2级,铸件加工后要求所有加工区域无可视缺陷。初始的铸造工艺主要在铸件精加工后的“碗底”区域出现可见的缩松缺陷。为了解决铸造缺陷,通过使用3D打印砂壳在铸件底部放置隔砂冷铁、使用MAGMASOFT铸造模拟软件的DOE分析功能布设冷筋等措施均无法根本解决“碗底”缩松问题,最终借助MAGMA软件在模拟分析后采用填平“碗底”的方案,通过粗加工去掉缺陷的方式,产品最终开发成功。

The piston in the high-speed rail braking system requires full body X-ray inspection and MT/PT inspection,with a defect level not exceeding level 2.After casting processing,all processing areas are required to have no visible defects.The initial casting process mainly results in visible shrinkage defects in the"bowl bottom"area after precision machining of the casting.In order to solve the casting defects,measures such as using 3D printed sand shells to place sand blocking cold iron at the bottom of the casting,and using the DOE analysis function of MAGMASOFT casting simulation software to lay cold bars cannot fundamentally solve the problem of"bowl bottom"shrinkage and looseness.Finally,after simulation analysis using MAGMA software,a plan of filling the"bowl bottom"was adopted,and the defects were removed through rough machining.The product was successfully developed.