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利用Magma软件对汽车发动机支架高压压铸(HPDC)过程进行数值模拟,验证了支架缺陷类型及位置与实际生产的一致性。分析得出了其气孔缺陷较高的原因是铸件高低分型大、壁厚不均及浇口过早的凝固,导致气体难以排出,且远端无法得到压力的良好作用,故形成气孔缺陷。通过分析气孔形成原因及其位置,设计局部挤压装置,利用局部挤压工艺解决远端承载孔周围存在的气孔缺陷问题。运用射线实时成像技术进行验证,从而建立将局部挤压工艺与高压压铸及CAE相结合的发动机支架铸件生产方式,使发动机支架局部气孔率降低至0.6%,有效提高了产品品质。
Magma software was used to simulate the high pressure die-casting (HPDC) process of automobile engine bracket, which verified the consistency of the type and location of the bracket defect with the actual production. It is concluded that the higher porosity and porosity of the castings are due to the high and low type of castings, the uneven wall thickness and the premature solidification of the gate, which makes the gas difficult to be discharged and the distal end can not get the good effect of the pressure. By analyzing the formation of stomata and its location, the design of partial extrusion device, the use of local extrusion process to solve the problem of stomatal defects around the distal bearing holes. The real-time radiography technology was used to verify the results. The production method of engine bracket castings, which combined the partial extrusion process with high pressure die casting and CAE, was established. The local porosity of the engine bracket was reduced to 0.6%, which effectively improved the product quality.