復(fù)雜水冷電機(jī)殼體的鑄造工藝設(shè)計(jì)及模具制造
發(fā)布時(shí)間：2019-06-24 23:38
【摘要】：隨著我國社會(huì)發(fā)展,國家對(duì)發(fā)動(dòng)機(jī)排放要求日趨嚴(yán)格,新能源發(fā)動(dòng)機(jī)的需求在與日俱增,新能源發(fā)動(dòng)機(jī)零部件的研發(fā)也正在受到越來越多的重視,其中電機(jī)殼體就是用于新能源機(jī)型的的一個(gè)大型關(guān)鍵零部件。該零件幾何結(jié)構(gòu)復(fù)雜,殼體壁內(nèi)帶循環(huán)水室,要求要有良好的力學(xué)性能和氣密性。復(fù)雜殼體零件的鑄造一直是鑄造行業(yè)的重點(diǎn)與難點(diǎn)。砂型鑄造在目前我國諸多鑄造企業(yè)中是應(yīng)用最為廣泛的,其優(yōu)點(diǎn)在于工藝成熟,成本低廉,但是鑄件毛坯余量大,容易產(chǎn)生各種鑄造缺陷。消失模鑄造由于其無需組芯,無須拔模斜度,所以使用消失模鑄造工藝的鑄件具有尺寸精確,加工余量少的特點(diǎn)。但是消失模鑄造也有著一定局限性,比如EPS泡沫模樣在燃燒過程中,熱解出的C原子會(huì)向金屬表面滲透,使得鑄件面產(chǎn)生碳夾雜的缺陷。而且EPS泡沫的強(qiáng)度比不上樹脂砂芯,在造型和振實(shí)過程中容易被擠壓變形,甚至塌箱。本文探討的是如何將兩種鑄造方式結(jié)合并解決復(fù)雜電機(jī)殼體零件的鑄造工藝難題。本文基于CAD/CAE技術(shù)對(duì)消失模的設(shè)計(jì)參數(shù)以及鑄造工藝參數(shù)進(jìn)行優(yōu)化,采用消失模-水道砂芯組合的鑄造工藝對(duì)GH電機(jī)殼體進(jìn)行開發(fā),并設(shè)計(jì)制作兩副消失模模具和一副冷芯盒模具,使用UG的CAM模塊對(duì)模具進(jìn)行加工編程,經(jīng)過調(diào)試后用生產(chǎn)出來的泡沫模與砂芯裝配澆鑄,生產(chǎn)出合乎產(chǎn)品設(shè)計(jì)使用要求的鑄件。根據(jù)本文研究,得到研究結(jié)果如下：(1)消失模和砂型鑄造的組合工藝是一種切實(shí)可行的鑄造工藝方法,以發(fā)泡的EPS材料顆粒翻制白模來表達(dá)GH電機(jī)殼體外形,以金屬模翻制水道冷砂芯來表達(dá)封閉循環(huán)水室,再將泡沫白模與水道冷砂芯組裝并用干砂充實(shí),最后進(jìn)行澆鑄成形。本文使用該方案,成功澆注出具有復(fù)雜外型和中空內(nèi)腔的電機(jī)殼體鑄件。(2)采用AnyCastiing軟件對(duì)鑄造過程進(jìn)行模擬仿真,采用不同的工藝參數(shù)模擬鑄造過程中澆注和凝固的變化過程,并對(duì)可能出現(xiàn)的缺陷進(jìn)行預(yù)測(cè),使工藝人員能夠根據(jù)要求采取更合理的澆注方案。(3)采用參數(shù)化的CAD軟件對(duì)電機(jī)殼體的模具進(jìn)行設(shè)計(jì),可以方便的調(diào)整各種參數(shù),在不斷調(diào)整各種模具參數(shù)的同時(shí),整個(gè)設(shè)計(jì)過程可視化程度高,提高了設(shè)計(jì)的準(zhǔn)確性和便利性。(4)使用CAM軟件對(duì)模具進(jìn)行編程加工,利用刀具特性,在CAM階段可以完成一些CAD階段的工作,比如模具的涂料層、拔模斜度、圓角等。(5)消失模鑄造在振實(shí)階段,砂粒對(duì)泡沫模型和砂芯沖擊都很大,必須采取增加芯骨或其他方式來增加模型強(qiáng)度；并且振實(shí)前要對(duì)泡沫模型的一些半封閉位置進(jìn)行特別檢查,這些部位填砂不飽滿會(huì)導(dǎo)致鑄件粘砂。(6)對(duì)于多方向脫模的模具,靈活采用多活塊的側(cè)抽結(jié)構(gòu)可以脫模,但是如果是人工操作的話就需要給活塊設(shè)計(jì)一定的導(dǎo)向機(jī)構(gòu),如槽或?qū)к?這樣才能保證人工裝模的一致性。對(duì)于深腔鑄鐵模具的加工,采用鑲拼式結(jié)構(gòu)可以節(jié)約大量刀具成本,同時(shí)也節(jié)約了加工時(shí)間。
[Abstract]:With the development of our country, the country's demand for engine emission is becoming more and more strict, the demand of new energy engine is increasing day by day, and the R & D of new energy engine parts is being paid more and more attention. The motor housing is a large-scale key component for new energy models. The geometric structure of the part is complicated, and the inner wall of the shell is provided with a circulating water chamber, so that good mechanical property and air tightness are required. The casting of complex shell parts has always been the focus and difficulty of the casting industry. Sand casting is the most widely used in many foundry enterprises in China. Its advantages are mature technology and low cost, but the margin of casting blank is large, and various casting defects can be easily produced. The lost foam casting process has the characteristics of accurate size and less processing allowance due to the need of no group core and no draft angle. However, the lost foam casting has some limitations, such as the EPS foam pattern in the combustion process, the pyrolytic C-atom can penetrate to the metal surface, so that the surface of the casting can produce the defect of carbon inclusion. And the strength of the EPS foam is not better than that of the resin sand core, and the EPS foam is easy to be extruded and deformed during the molding and compaction process, and even the tank is collapsed. In this paper, it is discussed how to combine two kinds of casting ways and to solve the problem of casting process of complicated motor case parts. In this paper, the design parameters of the lost foam and the parameters of the casting process are optimized based on the CAD/ CAE technology, and the shell of the GH motor is developed by the casting process of the combination of the lost foam-water channel sand core, and the two auxiliary lost foam moulds and a pair of cold core box dies are designed. And using the CAM module of the UG to process and program the mould, and after the debugging, the produced foam mould and the sand core are assembled and cast to produce the casting which is in accordance with the product design and use requirements. The results of the study are as follows: (1) The combined process of lost foam and sand mold casting is a feasible casting process, and the foamed EPS material particles are turned to the white mold to express the appearance of the GH motor shell. The cold sand core of the water channel is turned over by a metal mould to express the closed circulating water chamber, the foam white mould and the water channel cold sand core are assembled and the dry sand is enriched, and finally the casting is carried out. In this paper, the casting of motor shell with complex shape and hollow cavity is successfully cast. (2) The casting process is simulated and simulated by using the AnyCassing software, and the process of casting and solidification in the casting process is simulated with different process parameters, and the possible defects can be predicted, so that the process personnel can adopt more reasonable casting scheme as required. And (3) the parameterized CAD software is adopted to design the mould of the motor shell, various parameters can be conveniently adjusted, and meanwhile, the whole design process is high in visualization degree, and the design accuracy and the convenience are improved. And (4) using the CAM software to program and process the mould, and using the characteristic of the cutter, the work of some CAD stages can be finished in the CAM stage, such as the coating layer of the mould, the draft angle, the fillet, and the like. (5) When the lost foam is cast in the vibrating stage, the impact of the sand on the foam model and the sand core is large, the strength of the model must be increased by adding the core bone or other means, and the semi-closed position of the foam model is specially checked before the vibration is real, The incomplete filling of these parts will result in the casting of sand. (6) For a multi-direction demoulding mould, the side-drawing structure of the multi-movable block can be flexibly used for demoulding, but if the mould is manually operated, a certain guide mechanism, such as a groove or a guide rail, is required to be designed for the movable block, so that the consistency of the manual loading mould can be guaranteed. In that proces of the deep cavity cast iron mould, a large amount of tool cost can be saved by adopting a mosaic structure, and the processing time is also saved.
【學(xué)位授予單位】：廣西大學(xué)
【學(xué)位級(jí)別】：碩士
【學(xué)位授予年份】：2015
【分類號(hào)】：TM305
本文編號(hào)：2505458
[Abstract]:With the development of our country, the country's demand for engine emission is becoming more and more strict, the demand of new energy engine is increasing day by day, and the R & D of new energy engine parts is being paid more and more attention. The motor housing is a large-scale key component for new energy models. The geometric structure of the part is complicated, and the inner wall of the shell is provided with a circulating water chamber, so that good mechanical property and air tightness are required. The casting of complex shell parts has always been the focus and difficulty of the casting industry. Sand casting is the most widely used in many foundry enterprises in China. Its advantages are mature technology and low cost, but the margin of casting blank is large, and various casting defects can be easily produced. The lost foam casting process has the characteristics of accurate size and less processing allowance due to the need of no group core and no draft angle. However, the lost foam casting has some limitations, such as the EPS foam pattern in the combustion process, the pyrolytic C-atom can penetrate to the metal surface, so that the surface of the casting can produce the defect of carbon inclusion. And the strength of the EPS foam is not better than that of the resin sand core, and the EPS foam is easy to be extruded and deformed during the molding and compaction process, and even the tank is collapsed. In this paper, it is discussed how to combine two kinds of casting ways and to solve the problem of casting process of complicated motor case parts. In this paper, the design parameters of the lost foam and the parameters of the casting process are optimized based on the CAD/ CAE technology, and the shell of the GH motor is developed by the casting process of the combination of the lost foam-water channel sand core, and the two auxiliary lost foam moulds and a pair of cold core box dies are designed. And using the CAM module of the UG to process and program the mould, and after the debugging, the produced foam mould and the sand core are assembled and cast to produce the casting which is in accordance with the product design and use requirements. The results of the study are as follows: (1) The combined process of lost foam and sand mold casting is a feasible casting process, and the foamed EPS material particles are turned to the white mold to express the appearance of the GH motor shell. The cold sand core of the water channel is turned over by a metal mould to express the closed circulating water chamber, the foam white mould and the water channel cold sand core are assembled and the dry sand is enriched, and finally the casting is carried out. In this paper, the casting of motor shell with complex shape and hollow cavity is successfully cast. (2) The casting process is simulated and simulated by using the AnyCassing software, and the process of casting and solidification in the casting process is simulated with different process parameters, and the possible defects can be predicted, so that the process personnel can adopt more reasonable casting scheme as required. And (3) the parameterized CAD software is adopted to design the mould of the motor shell, various parameters can be conveniently adjusted, and meanwhile, the whole design process is high in visualization degree, and the design accuracy and the convenience are improved. And (4) using the CAM software to program and process the mould, and using the characteristic of the cutter, the work of some CAD stages can be finished in the CAM stage, such as the coating layer of the mould, the draft angle, the fillet, and the like. (5) When the lost foam is cast in the vibrating stage, the impact of the sand on the foam model and the sand core is large, the strength of the model must be increased by adding the core bone or other means, and the semi-closed position of the foam model is specially checked before the vibration is real, The incomplete filling of these parts will result in the casting of sand. (6) For a multi-direction demoulding mould, the side-drawing structure of the multi-movable block can be flexibly used for demoulding, but if the mould is manually operated, a certain guide mechanism, such as a groove or a guide rail, is required to be designed for the movable block, so that the consistency of the manual loading mould can be guaranteed. In that proces of the deep cavity cast iron mould, a large amount of tool cost can be saved by adopting a mosaic structure, and the processing time is also saved.
【學(xué)位授予單位】：廣西大學(xué)
【學(xué)位級(jí)別】：碩士
【學(xué)位授予年份】：2015
【分類號(hào)】：TM305
【參考文獻(xiàn)】
相關(guān)期刊論文 前10條
1 向承翔;;基于數(shù)值模擬的電機(jī)殼體鑄造工藝的優(yōu)化設(shè)計(jì)[J];鑄造技術(shù);2013年08期
2 高正宇;;成型高質(zhì)量消失模泡沫模型[J];鑄造技術(shù);2012年10期
3 黃裕飛;李曉棠;陳流;楊立權(quán);馮瀚;;基于AnyCasting的鎂合金缸蓋結(jié)構(gòu)設(shè)計(jì)與工藝參數(shù)優(yōu)化[J];鑄造;2012年05期
4 王新節(jié);;柴油機(jī)氣缸體消失模鑄造工藝的優(yōu)化設(shè)計(jì)[J];中國鑄造裝備與技術(shù);2012年01期
5 張棉好;;基于刀具壽命的切削參數(shù)優(yōu)化研究[J];新技術(shù)新工藝;2011年09期
6 朱麗娟;周源;王明娜;張喻;董秀奇;;消失模負(fù)壓鑄造澆注系統(tǒng)設(shè)計(jì)的探討[J];鑄造技術(shù);2009年07期
7 孫長富;邵娟;;大平板類鑄件實(shí)型鑄造工藝的實(shí)踐[J];鑄造技術(shù);2009年07期
8 王華僑;盛學(xué)斌;;鋁合金發(fā)動(dòng)機(jī)水冷雙層排氣管消失模鑄造成形技術(shù)應(yīng)用[J];金屬加工(熱加工);2009年01期
9 蘭冬云;郭敖如;;國內(nèi)外汽車發(fā)動(dòng)機(jī)鋁缸體鑄造技術(shù)[J];鑄造設(shè)備研究;2008年04期
10 張立強(qiáng);盧遠(yuǎn)志;張楚惠;劉金水;;基于計(jì)算機(jī)模擬的消失模鑄造充型特性[J];特種鑄造及有色合金;2008年02期
，本文編號(hào)：2505458
本文鏈接：http://sikaile.net/kejilunwen/dianlilw/2505458.html
最近更新
教材專著
