铝合金变速箱低压铸造充型与凝固的仿真及优化  

Simulation and Optimization on Filling and Solidification Process of Low-pressure Casting Aluminum Alloy Gearbox

作　　者：肖飞[1,2] 谢世坤[1,2] 张庭芳[2] 易荣喜[1] 应建中[1] 黄玉祥[1,2] 

机构地区：[1]井冈山大学机电工程学院,江西吉安343009 [2]南昌大学机电工程学院,江西南昌330031

出　　处：《热加工工艺》2015年第5期53-57,共5页Hot Working Technology

基　　金：国家自然科学基金项目(51165010);江西省高等学校科技落地计划项目(KJLD14066);江西省自然科学基金项目(20114 BAB206018);江西省青年科学家培养对象计划项目(赣科发计字[2010]209号)

摘　　要：以A356铝合金变速箱铸件为例,采用三维绘图软件Solidworks对变速箱进行3D造型,运用Pro CAST软件对其预定工艺的低压铸造充型和凝固过程进行了仿真。根据铸件充型的仿真结果,发现在充型过程中金属液面前沿出现参差不齐的现象。经验证分析这种现象主要是由于浇注系统设计不合理造成的。改变浇口位置后,金属液充型平稳。在铸件凝固后发现,在预定工艺中,变速箱上边缘以及浇口处产生了缩松缩孔的铸造缺陷,这是浇注温度过高引起的。根据仿真结果,进行了工艺优化,将浇注温度降低到700℃,再次进行铸造过程的仿真,发现缺陷得到了有效控制,铸件的质量获得明显改善。Taking A356 aluminum alloy gearbox casting as an example, 3D modeling of the gearbox was done by using three-dimensional reaping software Solidworks. The filling and solidification process of low pressure casting was simulated by using ProCAST software. According to the numerical simulation results of casting filling, it is discovered that the jagged surface frontier of metal liquid appears. Through the verification analysis, it is discovered that the phenomenon is caused mainly by the irrational gating system design. After changing the gate location, the mold filling of the liquid metal is steady. After the casting solidification, it is discovered that the upper edge of gearbox and the gate place produce casting defects of porosity and shrinkage. This is caused by the too high pouring temperature. According to the simulation results, the process was optimized. Reducing the pouring temperature to 700℃, the casting process was simulated again.It is found that defects are effectively controlled, and quality of the casting is obviously improved.

关 键 词：铝合金变速箱 低压铸造 仿真 工艺优化 

分 类 号：TG249.6[金属学及工艺—铸造]