大壁厚差复杂形状铝合金飞轮壳挤压铸造数值模拟  

Numerical simulation of squeeze casting of aluminum alloy flywheel housing with large wall thickness difference and complex shape

作　　者：姜巨福[1] 葛宁 黄敏杰 李明星[1] 王迎[2] 丁长杰 邹德超 Ju-fu JIANG;Ning GE;Min-jie HUANG;Ming-xing LI;Ying WANG;Chang-jie DING;De-chao ZOU(School of Materials Science and Engineering,Harbin Institute of Technology,Harbin 150001,China;School of Mechatronics Engineering,Harbin Institute of Technology,Harbin 150001,China;Dalian Innovation Die-casting Co.,Ltd.,Dalian 116600,China)

机构地区：[1]哈尔滨工业大学材料科学与工程学院,哈尔滨150001 [2]哈尔滨工业大学机电工程学院,哈尔滨150001 [3]大连创新压铸件有限公司,大连116600

出　　处：《Transactions of Nonferrous Metals Society of China》2023年第5期1345-1360,共16页中国有色金属学报（英文版）

基　　金：the National High Technology Research and Development Program of China(No.2019YFB2006503);the National Natural Science Foundation of China(No.51875124).

摘　　要：利用ProCAST软件对大壁厚差复杂形状ZL104铝合金飞轮壳挤压铸造过程进行数值模拟。结果表明:充型过程稳定且可分为4个阶段:流道连通、水平区域填充、竖直方向填充和难充填区填充。凝固过程中存在6个凝固滞后的特征区域,特征区域的缩孔缩松缺陷明显。缺陷位置预测准确,对预测的缺陷体积进行极差分析,确定最佳工艺参数为浇注温度650℃、比压48 MPa、模具温度220℃、补压比压800 MPa、补压延时10 s(A侧)和12 s(B侧)。最大铸造应力出现在凝固速度快、曲率大的薄壁结构中。仿真结果得到了实际工艺验证。The squeeze casting process of ZL104 aluminum alloy flywheel housing with large wall thickness difference and complex shape was simulated by ProCAST software.The results show that the filling process was stable and could be divided into four stages:connection of channels,filling of horizontal zone,vertical direction,and difficult-filling zone.There were six characteristic zones with solidification lag,where shrinkage cavity and shrinkage porosity were obvious.The location prediction of defects was accurate.Through range analysis of defects volume,the optimal combination of process parameters was determined as pouring temperature of 650℃,specific pressure of 48 MPa,mold temperature of 220℃,local specific pressure of 800 MPa,and pressure delay time of 10 s(Side A)and 12 s(Side B).The maximum stress occurred in the thin-walled structure with fast solidification and large curvature.The simulation results were verified by the actual process.

关 键 词：数值模拟 挤压铸造 大壁厚差 复杂形状 定域补压 

分 类 号：TG292[金属学及工艺—铸造]