重卡发动机缸盖模具设计及铸造工艺优化

Heavy-duty Truck Engine Cylinder Head Mold Design and Casting Process Optimization

介绍了模拟软件在重卡发动机缸盖的模具设计和铸造缺陷改善过程中的应用案例,指出:(1)判断浇注系统流动场的合理性,可通过模拟各浇道处铁液的流速,直观判断是否有铁液飞溅等,还可使用示踪粒子功能检查充型过程中是否存在卷气、紊流的情况,防止铸件产生氧化夹渣类缺陷;(2)使用等效应力、应变模拟可以准确判断铸件应力、应变集中的部位,结合铸件壁厚和材料的强度,评估是否需要对应力集中位置进行工艺补正,规避铸件开裂风险;(3)通过对铸件热节和热节模数大小进行模拟分析,在冒口使用受限制的情况下,可采用局部冷铁工艺来调节温度场,从而消除缩松缺陷。

The application case of simulation software in the mold design and casting defect improvement process of heavy truck engine cylinder head were introduced.The study concluded with the following points:(1)The rationality of the gating system's flow field could be assessed by simulating the flow velocity of molten iron at each ingate,allowing for a visual judgment of potential splashing.Additionally,tracer particle functions could be used to check for air entrapment or turbulence during mold filling,preventing oxidation and slag inclusion defects in the castings.(2)Using equivalent stress and strain simulations allowed for the accurate identification of stress and strain concentration areas in castings.By considering the wall thickness and material strength,it could be determined whether process adjustments were needed at stress concentration points to avoid cracking risks.(3)Through simulation analysis of the hot spot and the modulus of the hot spot in the casting,when the use of the riser was limited,the local chilling process could be used to adjust the temperature field and eliminate shrinkage defects.