铝合金盖板铸件轻量化设计与铸造工艺优化  

Lightweight Design and Casting Process Optimization of the Aluminum Alloy Cover Plate Casting

作　　者：李红强 朱广 李沛根 李文静 LI Hong-qiang;ZHU Guang;LI Pei-gen;LI Wen-jing(Xi′an Xikai Precision Foundry Co.,Ltd.,Xi′an 712046,Shaanxi,China)

机构地区：[1]西安西开精密铸造有限责任公司,陕西西安712046

出　　处：《铸造》2024年第12期1744-1750,共7页Foundry

摘　　要：应用ANSYS仿真软件辅助铝合金盖板铸件轻量化设计,并应用AnyCastingg铸造模拟软件辅助铸造工艺优化。ANSYS仿真结果表明,轻量化设计前,铸件满足水压破坏试验强度要求;壁厚减薄3 mm,铸件内腔两小凸台附近存在水压破坏试验破裂风险;将凸台根部圆角由R5 mm变为R10 mm,铸件破裂风险消除;进一步分析知,法兰减薄5 mm可行,减薄10 mm不可行。AnyCasting仿真结果表明,轻量化设计前,铸造工艺充型凝固过程良好,铸件没有缺陷;轻量化设计后,充型铝温较低,凝固出现多处缩孔和疏松缺陷;将充型速率由880 Pa/s提高至1100 Pa/s,问题消除。轻量化盖板铸件进行了生产试制,通过水压破坏试验验证。In this paper,ANSYS simulation software was used to assist in lightweight design of the aluminum alloy cover plate casting,and AnyCasting simulation software was used to assist in optimization casting process.The ANSYS simulation results showed that the strength of the casting met the requirement of the hydraulic failure test before lightweight design.When the thickness of the casting wall was reduced by 3 mm,and there was a rupture risk of hydraulic failure test near the two small boss of the inner cavity.By changing the rounded corner R5 mm to R10 mm at the base of the boss,the casting rupture risk was eliminated.Further analysis showed that it was feasible to reduce the flange thickness by 5 mm,but it was not feasible to reduce the flange thickness by 10 mm.The AnyCasting simulation results showed that the filling and solidification processes were good and the casting had no defect before lightweight design.After lightweight design,the aluminum liquid temperature was relatively low during the filling process,multiple shrinkage and porosity defects appeared in the casting solidification process.The filling rate was increased from 880 Pa/s to 1100 Pa/s,and the problems were eliminated.The trial production of the lightweight cover plate castings has been carried out and it has passed the validation of the hydraulic failure test.

关 键 词：铝合金 盖板铸件 轻量化设计 工艺优化 

分 类 号：TG292[金属学及工艺—铸造]