铝合金磁电机盖压铸成型数值模拟及工艺优化
发布时间：2018-12-12 01:25
【摘要】：压力铸造作为一种近净成形技术,在航空航天、车辆制造等行业应用非常广泛。随着全球工业的迅猛发展,铝合金压铸在铸造领域的比重逐渐提升。压铸过程十分复杂,过程中容易出现卷气、氧化夹杂、冷隔、气孔、粘模、缩孔缩松等问题。然而在实际生产中,企业往往依赖于经验反复调模试模来处理这些缺陷,以保证铸件的质量,但会使铸件生产成本增加、周期延长,同时削弱了企业的竞争力。本文针对铝合金磁电机盖在生产过程中出现粘模、冷隔及大量的缩孔缩松等缺陷导致产品的合格率低下的问题,采用AnyCasting软件模拟铸件压铸过程,并结合P-Q~2图技术与正交试验,获得压铸机与压铸模匹配性良好、模具结构设计合理、压铸工艺参数最佳的一套磁电机盖的生产方案,为企业提供一条解决问题的可行新路径。主要内容如下:(1)利用P-Q~2图技术研究了铸件原生产方案下的压铸系统,发现压铸机与压铸模匹配性低,提出更换压铸机的要求。借助数值模拟技术模拟铸件的充型过程及凝固过程,总结铸件缺陷产生的具体原因,针对各原因,改进了模具结构,并再次利用P-Q~2图技术评价更换的压铸机与改进模具的匹配性。(2)利用AnyCasting软件对优化模具结构后的铸件进行仿真模拟。结果显示:充型过程中金属液流动平稳,过程中无冷隔产生,凝固过程的温度场分布更加均衡,厚大部位的缩孔缩松得到改善,同时改进方案的粘模概率降低。之后将改进方案的推出机构的推杆进行重新设计,改进方案选用直径8mm,数量为39根的推杆,此时各推杆的稳定性校核显示均合理。(3)利用正交试验法,研究了合金浇注温度、模具预热温度及冲头压射速度三个参数对磁电机盖缩孔缩松缺陷的影响,发现浇注温度对铸件的缩孔缩松的形成影响最大,模具预热温度的影响次之,压射速度的影响最小;同时进一步分析试验结果得到一组保证铸件品质的最佳工艺参数:浇注温度630℃、模具预热温度170℃、压射速度2.1m/s。(4)将改进后的模具以最佳生产工艺参数在更换的压铸机上进行铸件生产验证。结果表明:实际结果与模拟结果基本吻合,铸件表面的冷隔缺陷基本消除,粘模概率得到有效降低,同时厚大部位的缩孔缩松程度明显减轻,铸件的整体质量满足企业要求。
[Abstract]:As a near-net forming technology, pressure casting is widely used in aerospace, vehicle manufacturing and other industries. With the rapid development of global industry, the proportion of aluminum alloy die-casting in the field of casting gradually increased. The process of die casting is very complicated, such as winding gas, oxidizing inclusion, cold barrier, porosity, sticking die, shrinkage porosity and so on. However, in actual production, enterprises often rely on the experience to repeatedly adjust the mold to deal with these defects, to ensure the quality of castings, but it will increase the cost of casting production, prolong the period, and weaken the competitiveness of enterprises. Aiming at the problems of low pass rate caused by defects such as die sticking, cold barrier and a large number of shrinkage holes in aluminum alloy magnetomotor cap during production, this paper uses AnyCasting software to simulate the die casting process of castings. Combined with P-Q~2 diagram technology and orthogonal test, a set of magnetic motor cover production scheme is obtained, which has good matching with die casting die, reasonable die structure design and optimum die casting process parameters. To provide an enterprise with a feasible new path to solve the problem. The main contents are as follows: (1) the die-casting system under the original production plan is studied by using P-Q~2 diagram. It is found that the matching between die-casting machine and die casting die is low, and the requirement of replacing die-casting machine is put forward. The mold filling process and solidification process of castings are simulated by numerical simulation technology. The specific causes of casting defects are summarized, and the die structure is improved for each reason. The matching between the replaced die-casting machine and the improved die is evaluated by the P-Q~2 diagram technique again. (2) the simulation of the optimized die structure castings is carried out by using the AnyCasting software. The results show that the liquid metal flows smoothly during the filling process, no cold barrier occurs during the process, the distribution of the temperature field in the solidification process is more balanced, the shrinkage and porosity of the thick and large parts are improved, and the probability of bonding of the improved scheme is reduced. After that, the putter rod of the push mechanism of the improved scheme is redesigned. The improved scheme selects the push rod with a diameter of 8 mm and a number of 39. At this time, the stability check of each putter is reasonable. (3) the orthogonal test method is used to verify the stability of each putter. (3) the orthogonal test method is used. The effects of alloy pouring temperature, die preheating temperature and punch injection speed on shrinkage defects of magnetomotor cover are studied. It is found that pouring temperature has the greatest influence on the formation of shrinkage hole shrinkage of casting, and the influence of die preheating temperature on the formation of shrinkage hole shrinkage is the second. The impact of injection velocity is the least; At the same time, through further analysis of the test results, a group of optimum technological parameters to guarantee the casting quality are obtained: pouring temperature 630 鈩，
本文编号：2373616
[Abstract]:As a near-net forming technology, pressure casting is widely used in aerospace, vehicle manufacturing and other industries. With the rapid development of global industry, the proportion of aluminum alloy die-casting in the field of casting gradually increased. The process of die casting is very complicated, such as winding gas, oxidizing inclusion, cold barrier, porosity, sticking die, shrinkage porosity and so on. However, in actual production, enterprises often rely on the experience to repeatedly adjust the mold to deal with these defects, to ensure the quality of castings, but it will increase the cost of casting production, prolong the period, and weaken the competitiveness of enterprises. Aiming at the problems of low pass rate caused by defects such as die sticking, cold barrier and a large number of shrinkage holes in aluminum alloy magnetomotor cap during production, this paper uses AnyCasting software to simulate the die casting process of castings. Combined with P-Q~2 diagram technology and orthogonal test, a set of magnetic motor cover production scheme is obtained, which has good matching with die casting die, reasonable die structure design and optimum die casting process parameters. To provide an enterprise with a feasible new path to solve the problem. The main contents are as follows: (1) the die-casting system under the original production plan is studied by using P-Q~2 diagram. It is found that the matching between die-casting machine and die casting die is low, and the requirement of replacing die-casting machine is put forward. The mold filling process and solidification process of castings are simulated by numerical simulation technology. The specific causes of casting defects are summarized, and the die structure is improved for each reason. The matching between the replaced die-casting machine and the improved die is evaluated by the P-Q~2 diagram technique again. (2) the simulation of the optimized die structure castings is carried out by using the AnyCasting software. The results show that the liquid metal flows smoothly during the filling process, no cold barrier occurs during the process, the distribution of the temperature field in the solidification process is more balanced, the shrinkage and porosity of the thick and large parts are improved, and the probability of bonding of the improved scheme is reduced. After that, the putter rod of the push mechanism of the improved scheme is redesigned. The improved scheme selects the push rod with a diameter of 8 mm and a number of 39. At this time, the stability check of each putter is reasonable. (3) the orthogonal test method is used to verify the stability of each putter. (3) the orthogonal test method is used. The effects of alloy pouring temperature, die preheating temperature and punch injection speed on shrinkage defects of magnetomotor cover are studied. It is found that pouring temperature has the greatest influence on the formation of shrinkage hole shrinkage of casting, and the influence of die preheating temperature on the formation of shrinkage hole shrinkage is the second. The impact of injection velocity is the least; At the same time, through further analysis of the test results, a group of optimum technological parameters to guarantee the casting quality are obtained: pouring temperature 630 鈩，
本文编号：2373616
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