复杂薄壁汽车车门压铸过程数值模拟及缺陷预测  

Numerical Simulation and Defect Prediction of Complex Thin-Walled Automotive Door Die-Casting

作　　者：刘宝林 廖铭煜 姚佳宏 安肇勇 张伟 万里 康进武 LIU Bao-in;LIAO Ming-yu;YAO Jia-hong;AN Zhao-yong;ZHANG Wei;WAN Li;KANG Jin-wu(Key Laboratory ofAdvanced Forming Manufacturing,Ministry of Education,School of Materials,Tsinghua University,Beijing 100084,China;Beijing Shichuang Technology Co.,Ltd.,Beijing 100083,China;Guangdong Hongtu Technology Co.,Ltd.,Zhaoqing 526108,Guangdong,China)

机构地区：[1]清华大学材料学院,先进成形制造教育部重点实验室,北京100084 [2]北京适创科技有限公司,北京100083 [3]广东鸿图科技股份有限公司,广东肇庆526108

出　　处：《铸造》2025年第3期385-391,共7页Foundry

基　　金：广东省重点领域研发计划新能源汽车铝合金超大型结构件制造成型技术项目(No.2022B0909070001)。

摘　　要：为解决高压压铸铝合金大型复杂薄壁汽车车门压铸过程中气孔和缩孔等问题,运用SuperCAST智铸超云CAE云计算平台对其高压铸造过程流场和温度场进行模拟分析,预测铸件内部缺陷分布,并进行工艺优化和试验验证。结果表明:采用两段速慢压射工艺方案A和B分别出现充填时间长和温度分布不均等情况,而方案C采用匀加速慢压射工艺,其充填时间和温度的均匀性均较合理。凝固模拟分析发现,随着增压压力的提高显著减少了方案C的缩松缩孔含量,90 MPa时完全消除缺陷。综合来看,方案C表现优于方案A,因其不存在料管卷气现象,且充填温度更均匀,整体缺陷控制效果更好。优化的压铸生产工艺为方案C,其低速压射采用匀加速压射工艺,最高临界速度为1.23 m/s,高速速度为4.6 m/s,起高速位置为900mm,增压压力为90MPa,现场压铸试验验证了该压射工艺的可行性。To address the issues of porosity and shrinkage defects in the high-pressure die casting process of large,complex,thin-walled aluminum alloy automotive door shells,the CAE cloud computing platform,SuperCAST,was used to optimize the casting process.The simulation involved analyzing the flow field and thermal field to predict the locations of internal defects in the casting,followed by experimental validation using the optimized shot process.The results showed that using two-stage slow-shot process A and B result in long filling time and uneven thermal distribution,respectively.In contrast,scheme C,utilizing a uniform acceleration slow-shot process,ensured better uniformity in both filling time and temperature.Solidification simulation analysis showed that increasing the intensification pressure significantly reduced shrinkage porosity in scheme C,with these defects being completely eliminated at 90 MPa.Overall,scheme C outperformed scheme A,as it exhibited no gas entrapment in sleeve and achieved more uniform filling temperature,resulting in better defect control.The optimized shot process was based on scheme C,featuring uniform acceleration in the slow-shot stage,with a maximum critical speed of 1.23 m/s,a high-speed of 4.6 m/s,and a high-speed position of 900 mm,with an intensification pressure of 90 MPa.Trail production validated the feasibility of the scheme C.

关 键 词：压铸 汽车车门 增压压力 缩孔 模拟分析 工艺优化 

分 类 号：TG146.21[一般工业技术—材料科学与工程] TG249.2[金属学及工艺—金属材料]