鋁合金磁電機蓋壓鑄成型數(shù)值模擬及工藝優(yōu)化
發(fā)布時間：2018-12-12 01:25
【摘要】：壓力鑄造作為一種近凈成形技術(shù),在航空航天、車輛制造等行業(yè)應(yīng)用非常廣泛。隨著全球工業(yè)的迅猛發(fā)展,鋁合金壓鑄在鑄造領(lǐng)域的比重逐漸提升。壓鑄過程十分復(fù)雜,過程中容易出現(xiàn)卷氣、氧化夾雜、冷隔、氣孔、粘模、縮孔縮松等問題。然而在實際生產(chǎn)中,企業(yè)往往依賴于經(jīng)驗反復(fù)調(diào)模試模來處理這些缺陷,以保證鑄件的質(zhì)量,但會使鑄件生產(chǎn)成本增加、周期延長,同時削弱了企業(yè)的競爭力。本文針對鋁合金磁電機蓋在生產(chǎn)過程中出現(xiàn)粘模、冷隔及大量的縮孔縮松等缺陷導(dǎo)致產(chǎn)品的合格率低下的問題,采用AnyCasting軟件模擬鑄件壓鑄過程,并結(jié)合P-Q~2圖技術(shù)與正交試驗,獲得壓鑄機與壓鑄模匹配性良好、模具結(jié)構(gòu)設(shè)計合理、壓鑄工藝參數(shù)最佳的一套磁電機蓋的生產(chǎn)方案,為企業(yè)提供一條解決問題的可行新路徑。主要內(nèi)容如下:(1)利用P-Q~2圖技術(shù)研究了鑄件原生產(chǎn)方案下的壓鑄系統(tǒng),發(fā)現(xiàn)壓鑄機與壓鑄模匹配性低,提出更換壓鑄機的要求。借助數(shù)值模擬技術(shù)模擬鑄件的充型過程及凝固過程,總結(jié)鑄件缺陷產(chǎn)生的具體原因,針對各原因,改進了模具結(jié)構(gòu),并再次利用P-Q~2圖技術(shù)評價更換的壓鑄機與改進模具的匹配性。(2)利用AnyCasting軟件對優(yōu)化模具結(jié)構(gòu)后的鑄件進行仿真模擬。結(jié)果顯示:充型過程中金屬液流動平穩(wěn),過程中無冷隔產(chǎn)生,凝固過程的溫度場分布更加均衡,厚大部位的縮孔縮松得到改善,同時改進方案的粘模概率降低。之后將改進方案的推出機構(gòu)的推桿進行重新設(shè)計,改進方案選用直徑8mm,數(shù)量為39根的推桿,此時各推桿的穩(wěn)定性校核顯示均合理。(3)利用正交試驗法,研究了合金澆注溫度、模具預(yù)熱溫度及沖頭壓射速度三個參數(shù)對磁電機蓋縮孔縮松缺陷的影響,發(fā)現(xiàn)澆注溫度對鑄件的縮孔縮松的形成影響最大,模具預(yù)熱溫度的影響次之,壓射速度的影響最小;同時進一步分析試驗結(jié)果得到一組保證鑄件品質(zhì)的最佳工藝參數(shù):澆注溫度630℃、模具預(yù)熱溫度170℃、壓射速度2.1m/s。(4)將改進后的模具以最佳生產(chǎn)工藝參數(shù)在更換的壓鑄機上進行鑄件生產(chǎn)驗證。結(jié)果表明:實際結(jié)果與模擬結(jié)果基本吻合,鑄件表面的冷隔缺陷基本消除,粘模概率得到有效降低,同時厚大部位的縮孔縮松程度明顯減輕,鑄件的整體質(zhì)量滿足企業(yè)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，
本文編號：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，
本文編號：2373616
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