ZL101齿轮箱箱体砂型铸造工艺优化  

Design and Optimization of Sand Casting Process for Aluminum Alloy Gearbox Body

作　　者：陈鹏飞 米国发[1] 王建军 毛长城 许磊[1] CHEN Peng-fei;MI Guo-fa;WANG Jian-jun;MAO Chang-cheng;XU Lei(School of Materials Science and Engineering,Henan Polytechnic University,Jiaozuo 454000,Henan,China;Henan Plain Photoelectric Co.,Ltd.,Jiaozuo 454001,Henan,China)

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 [2]河南平原光电科技有限公司,河南焦作454001

出　　处：《铸造》2018年第12期1090-1094,共5页Foundry

基　　金：河南省科技攻关项目(172102210287)

摘　　要：根据齿轮箱箱体的结构特点及技术要求,选择砂型铸造方法进行铸造工艺设计,选择树脂砂作为造型材料。利用ViewCast软件进行充型和凝固模拟,预测铸造缺陷产生位置,分析了充型和凝固过程中铸件产生缺陷的原因。在此基础上,对齿轮箱箱体的铸造工艺方案进行了优化,最终选择阶梯式浇注系统,直浇道、横浇道、内浇道截面积比为1:2:4,冒口选择发热保温冒口,浇注温度为750℃。使用优化后的铸造工艺方案进行了数值模拟及实际浇注试验,发现铸件几乎没有缺陷,满足了实际生产中对铸件质量的要求。Based on the structural characteristics and technical requirements of the gearbox body,the sand casting process was chosen and designed to produce the castings,in which the resin sand was selected as the molding material.The filling and solidification processes of the gearbox bodywere simulated by the software of ViewCast,in order to predict the location of casting defects.By analyzing the causes of defects during the filling and solidification processes,the original casting process scheme was optimized.Finally,for the optimized casting process scheme,the stepped gating system was selected,the cross-sectional area ratio of the sprue,runner and gate was set as 1:2:4.Meanwhile,the thermal insulation riser was used and the pouring temperature was determined to be 750℃.With the optimized casting process scheme,the simulation and practical pouring tests were conducted,and the result shows that there is almost no defect in the casting,which meets the actual quality requirements of the gearbox bodies.

关 键 词：齿轮箱箱体 树脂砂铸造 铝合金 工艺优化 

分 类 号：TG146.2[一般工业技术—材料科学与工程]