某零件压力铸造工艺仿真分析

论文总字数：26431字

摘 要

Abstract…………………………………………………………………………….…..6

第一章 绪论…………………………………………………………………………7

1.1 研究背景………………………………………………………………….…7

1.2 铝合金……………………………………………………………………….7

1.3压力铸造……………………………………………………………………..7

1.4 数值模拟…………………………………………………………………….8

第二章 铸造充型和Procast数值模拟技术………………………………………..9

2.1 引言…………………………………………………………………………9

2.2 充型凝固过程中的数值模拟计算技术综述………………………………9

2.3 充型凝固过程中计算模拟的主要内容及方法……………………………10

2.3.1 处理过程………………………………..…………………………..10

2.3.2 数值模拟方法………………………………..……………………..10

2.3.3流场模拟………………………………. ……………………………11

2.4 ProCAST数值模拟软件简介. ………………………………..….…...….12

2.4.1 主要功能模块………………………………..………………….…12

2.4.2 模拟分析能力………………………………..………………….…13

2.4.3 ProCAST的主要特点………………………………..……………13

2.5 研究内容简述………………………………..……………………….……14

第三章 零件铸型的仿真模拟………………………………..………………….…..15

3.1 零件描述………………………………..…………………………….……..15

3.2 ProCAST模拟步骤………………………………..………………….…….15

3.2.1 Mesh阶段………………………………..……………………….….15

3.2.2 Cast阶段………………………………..……………………….…...17

3.2.3 Viewer阶段………………………………..……………………..…..20

3.3压力铸造工艺的主要参数………………………………..……………….....21

第四章 模拟实验结果分析设置………………………………..…………………....23

4.1 缩孔缩松分析………………………………..……………………….….….23

4.2单因素轮换法………………………………..………………………….…...23

4.2.1 最佳浇铸温度………………………………..…………………..…..23

4.2.2 最佳模具预热温度………………………………..……………..…..26

4.2.3 最佳压射速度（比压）………………………………..……………27

4.3 正交实验………………………………..………………………………..….28

第五章 总结………………………………..…………………………………..……..31

致谢………………………………..…………………………………………..………32

参考文献………………………………..……………………………………..………33

摘 要

压力铸造技术是一种常见的生产方式，铝合金铸件以其优异的性质被人们所青睐。随着计算机软硬件的发展，模拟铸件成型的结果也越来越精确。数值模拟在生产中的地位也越来越重要。

本文以某深腔、筒形零件的压铸工艺为研究对象，利用ProCAST软件，对零件的整个压铸过程进行模拟。通过单元素轮换法和正交实验法两种方法，以缩孔缩松为缺陷判据标准，研究浇铸温度、模具预热温度和压射速度对最终成型铸件质量的影响。

在对结果进行分析后，单元素轮换法能较为清晰的得到不同工艺参数对缺陷形成趋势的影响。当浇铸温度为单一变量时，可以看出在630℃以前，即有较低的浇铸温度时能有更好的铸件质量，在630℃时有着最小的缺陷，之后随着温度的升高，缺陷也不断地增加而且比低温时更多；当以模具预热温度为变量时，在预热温度达到220℃以前，缺陷一直减少，之后预热温度的升高对最终缺陷的形成影响并不显著；当以压射速度为变量时，而压射速度需要在一个合适的区间内才能有最好的铸件质量，即在7m/s-10m/s时质量较好，在为10m/s达到最佳值，大于或者小于这个区间都会使缺陷增加。但是最终，在确定最佳工艺参数时，因为各个参数有交互影响的关系，所以并不准确。

当通过正交实验法可以计算出浇铸温度对最终铸件的质量影响最大，模具预热温度次之，压射速度影响最小，同时得到了较为准确的最佳工艺参数。

关键词：压力铸造 铝合金 数值模拟 ProCAST

Abstract

Die-casting technology is a common production mode. Aluminum alloy castings are favored by people for their excellent properties. With the development of computer software and hardware, the simulation results of casting forming are more and more accurate. The position of numerical simulation in production is becoming more and more important.

In this paper, the die casting process of a deep cavity and cylindrical part is taken as the research object, and the whole die casting process of the part is simulated by ProCAST software. Through the two methods of single element rotation method and orthogonal experiment method, the shrinkage porosity is used as the criterion of defect criterion, and the influence of casting temperature, mold preheating temperature and injection speed on the quality of final molded casting is studied.

After analyzing the results, the single element rotation method can clearly obtain the influence of different process parameters on the defect formation trend. When the casting temperature is a single variable, it can be seen that before 630 ° C, there is a lower casting temperature, there is better casting quality, there is a minimum defect at 630 ° C, and then with the increase of temperature, the defect It is also increasing continuously and more than at low temperatures; when the preheating temperature of the mold is used as a variable, the defect is always reduced before the preheating temperature reaches 220 °C, and then the increase in the preheating temperature has no significant effect on the formation of the final defect. When the injection speed is a variable, the injection speed needs to be in a suitable interval to have the best casting quality, that is, the quality is better at 7m/s-10m/s, and the highest at 10m/s. When a value is greater than or less than this interval will increase the defect. But in the end, when determining the optimal process parameters, it is not accurate because each parameter has an interactive relationship.

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