E-80缸体的铸造工艺模拟优化及应力分析  

Simulation and Optimization of Casting Process and Stress Analysis of E-80 Cylinder Body

作　　者：米国发[1] 刘彦磊[1] 赵恒涛[1] 

机构地区：[1]河南理工大学材料科学与工程学院,河南焦作454000

出　　处：《热加工工艺》2009年第3期40-44,共5页Hot Working Technology

基　　金：河南省杰出人才创新基金项目(0621000700)

摘　　要：在E-80缸体低压铸造过程中,在关键部位产生缩孔缺陷,对产品质量造成不良影响。采用Z-CAST软件对缸体充型及凝固过程进行模拟,依据模拟结果对原始工艺进行改进。在不影响铸件使用性能的前提下改变加强筋位置,建立补缩通道,有效地对关键部位进行了补缩;在模具相应部位嵌入传热系数较大的铜块,改变不合理的凝固顺序,使铸件中形成了有利于补缩的凝固顺序。通过工艺改进,消除了关键部位的缩孔缺陷。对工艺改进后的最佳方案生产的铸件进行应力分析,最大应力出现在铸件底部及厚大部位的内侧,最大应力值为115MPa,小于ZL102的抗拉强度及抗剪强度,铸件不会产生裂纹。The shrinkage defect was formed easily at critical location during low prcssure die casting of E-80 cylinder body, which had harmful effect on the products. The mold filling and solidification process of the cylinder body was simulated by Z-CAST software. The casting technique was improved based on the simulation results. In order to create effective feeding passage, the structure of casting was modified by changing the location of strengthening ribs at the bottom. Inserting copper billet at snitable location of the die was a valid way to create suitable solidification sequence that is beneficial to the feeding. Using these techniques, shrinkage defect was completely eliminated at the critical location. And the stress distribution of cylinder body produced by optimum technique was analyzed. The maximum stress value was 115MPa, which appeared at bottom of casting and inside location of thick and large part. Because it was less than the tensile strength value and shear strength value of ZL102, the casting crack would not be formed.

关 键 词：缸体 模拟 工艺优化 铸造应力 

分 类 号：TG244.1[金属学及工艺—铸造]