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在DISA线生产汽车离合器压盘铸件时,铸件出现了严重的缩孔缺陷,导致了产品报废。运用铸造模拟软件ProCAST对铸件充型和凝固过程进行模拟,分析缺陷产生的原因。根据模拟结果优化原始工艺,将原底注式浇注工艺改为阶梯式浇注,缩短补缩浇道的长度、加大补缩浇道截面和冒口的尺寸,同时在冒口颈附近设置补贴。对改进后的工艺再进行模拟,发现中间层浇道提前进浇,出现了严重的冲刷和裹气。对工艺再次进行优化,将中间层浇道向上倾斜并减小其截面,同时增大底层浇道的截面;将浇注温度降低至1350℃。采用二次改进后的工艺生产的铸件缩孔缺陷消除,铸件质量完好,成品率大幅度提升。
In the production of automotive clutch pressure plate DISA castings, casting a serious shrinkage defects, resulting in product scrap. Casting simulation software ProCAST was used to simulate the process of filling and solidification of castings, and the causes of defects were analyzed. According to the simulation results to optimize the original process, the original bottom pouring casting process to ladder-type pouring, shortening the length of the retract runner, increasing the size of the sprue section and riser feeding, and set a subsidy near the spout neck. After the simulation of the improved process, found that the middle layer of runner advance into the pouring, there have been serious erosion and wrap. The process was again optimized by tilting the middle runner upwards and reducing its cross section while increasing the cross section of the bottom runner; reducing the pouring temperature to 1350 ° C. Adopting the second improved technology to eliminate the shrinkage defects of the castings, the quality of the castings is good and the yield of the castings is greatly improved.