注塑机支座铸造工艺设计及数值模拟  

Design and Numerical Simulation of Casting Process for Bearing of Injection Molding Machine

作　　者：徐超 李嘉倩 季德生 龙秀慧 XU Chao;LI Jiaqian;JI Desheng;LONG Xiuhui(Department of Mechanical and Electrical Engineering,Binzhou University,Binzhou 256600,China)

机构地区：[1]滨州学院机电工程学院,山东滨州256600

出　　处：《中北大学学报（自然科学版）》2022年第6期514-521,529,共9页Journal of North University of China(Natural Science Edition)

基　　金：山东省重点研发计划软科学项目(2019RKB01384);滨州市科学技术发展计划软科学项目(2018BRK15);国家安全生产重大事故防治关键技术科技项目(shandong-0020-2014AQ);滨州学院科研基金项目(BZXYG1211,BZXYG1409)。

摘　　要：以卧式注塑机合模系统中的支座为研究对象,对支座砂型铸造工艺进行了设计.利用MATLAB来优化炉料配比,以保证铁液的熔炼质量,优化后的炉料配比为:Z15生铁占93%,回炉料占1.5%,废钢占5.45%,硅铁占0.015%,锰铁占0.035%.同时,通过计算得到QT500-7中除铁以外各元素的精确比例为:C为3.54%,Si为2.15%,Mn为0.53%,S为0.02%,P为0.05%,Mg为0.05%,RE为0.04%.铸造中采用了充型平稳快速且挡渣能力较强的底注式封闭式浇注系统,根据铸铁件均衡凝固的原则设计了补缩系统与激冷系统,采用了压边冒口和石墨冷铁;利用Creo5.0软件建立了铸件、浇注系统、补缩系统以及激冷系统模型,并将模型导入ProCAST软件对初始工艺方案进行了数值模拟.模拟结果显示,支座铸件的前座与连接侧壁部位有较多孔隙度达5%以上的缩孔和缩松缺陷,且测得的单个铸件的缩松、缩孔总体积约为35.68 cm^(3).根据初始工艺方案的模拟结果,对铸件前座部位的冒口和冷铁布置进行了改进.改进后的工艺方案模拟结果表明,铸件本体部分无气孔缺陷;当碳当量为3.54%时,球铁膨胀量约为0.45%,剩余孔隙度超过5%的缩松缺陷体积仅为2.03 cm^(3),且缺陷可以通过球铁石墨化自补缩来消除.Taking the bearing in the clamping system of horizontal injection molding machine as the research object,the casting process of bearing was designed.MATLAB was used to optimize the charge ratio to ensure the smelting quality of molten iron.The optimized charge ratio was 93%Z15 pig iron,1.5%return charge,5.45%scrap steel,0.015%ferrosilicon and 0.035%ferromanganese.At the same time,the exact proportion of each element in QT500-7 was obtained through calculation,in which C was 3.54%,Si was 2.15%,Mn was 0.53%,S was 0.02%,P was 0.05%,Mg was 0.05%and RE was 0.04%.The bottom injection type closed gating system with stable and fast filling and strong slag retaining ability was adopted.The design of feeding system and chilling system was based on the principle of balanced solidification of cast iron,and adopts blank holder riser and graphite chillers.Creo5.0 software was used to establish casting,pouring system,feeding system and chilling system models,and ProCAST software was imported to conduct numerical simulation of the initial process scheme.The simulation results show that there are many shrinkage holes and porosity defects with porosity above 5%in the front seat and connecting side wall of the bearing casting,and the total volume of shrinkage cavity and porosity of a single casting is about 35.68 cm^(3).According to the simulation results of the initial process scheme,the riser and chillers layout of the front seat of the casting were optimized.The simulation results of the improved process scheme show that there is no porosity defect in the casting body.When the carbon equivalent is 3.54%,the expansion of ductile iron is about 0.45%,and the volume of shrinkage defects with residual porosity over 5%is only 2.03 cm^(3),so the defects can be eliminated by the graphite self-feeding of ductile iron.

关 键 词：支座 MATLAB 均衡凝固 PROCAST 注塑机 铸造工艺 

分 类 号：TG242.3[金属学及工艺—铸造]