基于ProCAST的汽车制动鼓消失模铸造工艺优化

Optimization of Lost-foam Casting Process of Automobile Brake Hub Based on ProCAST Software

针对汽车制动鼓铸件在实际生产中存在的缩孔、缩松问题,通过ProCAST软件对制动鼓消失模铸造工艺进行数值模拟,分析了铸件温度场对铸件缩松缩孔缺陷的影响,并对消失模铸造汽车制动鼓工艺方案进行了优化。结果表明,采用底部注入式浇注系统,液态金属在充型过程中均匀平稳并且能够充满铸型型腔,通过在铸件顶部加环形冒口以及增加铸件顶部内壁壁厚,可以有效地改善凝固过程中的温度场,降低铸件出现缩松、缩孔的几率,使缩松、缩孔缺陷基本出现在直浇道中。对铸件进行X射线检测,实际生产汽车制动鼓铸件内部无缩松、缩孔缺陷,提高了铸件的合格率。

For solving the problems existing in the actual production of automobile brake hub castings,the lost foam casting process of automobile brake hubs was simulated by the ProCAST software.The influence of the temperature field of the castings on the shrinkage cavities and porosity was analyzed,and the process optimization of the lost foam casting process was carried out.The results show that with the bottom injection type pouring system,the metal liquid filling process presents even and stable to fully fill the cavity.By adding a ring riser on the top and increasing the wall thickness of the top wall of the castings,the temperature field during the solidification process can be improved effectively,and the potential shrinkage cavities and porosity in the brake hub are reduced,and the shrinkage cavities and porosity are basically distributed in the sprue.There are absence of shrinkage porosity(holes)in the brake hub by using X-ray,greatly improving the qualified rate of the castings.