基于Magma数值模拟的汽油机活塞铸造过程优化
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摘要
利用Magma软件对某汽油机铝合金活塞铸造过程进行了数值模拟,根据出现的铸造缺陷类型及位置对铸造模具进行了优化。结果表明,在顶模前端增加铝液存储槽后,避免了前端容易被氧化的铝液在顶面停留,从而减少铝液填充到顶面时因模具排气不畅而形成的气孔缺陷,并运用染色及CT扫描检测技术验证了模拟结果与实际生产的一致性。通过小批量生产验证,活塞顶面铸造缺陷由原来的50%降低至5%以内,有效地解决了活塞顶面铸造缺陷,提高了产品品质。
The casting process of aluminum alloy piston for a gasoline engine was simulated by Magma software.The mould was optimized according to the types and location of casting defects.The results reveal that the liquid aluminum storage tank on the front end of top die can avoid the liquid aluminum that is easily oxidized in front remaining on the top,so as to reduce the air hole defects caused by poor exhausting of the mold when the aluminum liquid is filled to the top surface.The consistency between the simulated results and the actual production has been verified by dyeing and CT scanning technology.Through small batch production verification,piston top casting defects has been reduced from 50%to less than 5%,solving effectively the casting defects on the top surface and improving the product quality.
The casting process of aluminum alloy piston for a gasoline engine was simulated by Magma software.The mould was optimized according to the types and location of casting defects.The results reveal that the liquid aluminum storage tank on the front end of top die can avoid the liquid aluminum that is easily oxidized in front remaining on the top,so as to reduce the air hole defects caused by poor exhausting of the mold when the aluminum liquid is filled to the top surface.The consistency between the simulated results and the actual production has been verified by dyeing and CT scanning technology.Through small batch production verification,piston top casting defects has been reduced from 50%to less than 5%,solving effectively the casting defects on the top surface and improving the product quality.
引文
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[2]邬智立.发动机铝合金活塞铸件缺陷分析及铸造工艺改进[J].铸造,2018,67(1):48-45.
[3]饶牧成.铝活塞材料性能增强途径探讨[J].特种铸造及有色合金,2011(S):77-79.
[4]SUN L,LI C A,TU J W,et al.Effect of surface treatment to inserted ring on Al-Fe bonding layer of aluminium piston with reinforced cast iron ring[J].Journal of Central South University,2014,21(8):3 037-3 042.
[5]赵群宪,衣延山,王勇杰,等.改进浇注系统解决铸件缩孔缺陷[J].现代铸铁,2012,32(4):51-54.
[6]汪学阳,黄志垣,陈振宇.基于数值模拟的铝合金冷却模块的压铸工艺开发[J].特种铸造及有色合金,2017,37(10):1 078-1 080.
[7]SEVERINO G,PAIVA E J,FERREIRA J R,et al.Developmentof a special geometry carbide tool for the optimization of vertical turning of martensitic gray cast iron piston rings[J].The International Journal of Advanced Manufacturing Technology,2012,63:5-8.
[8]KASALA J,PERNIS R,ˇCAPLOVIˇCL’,et al.Influence of gating system design on tensile properties of AlSi7Mg0.3alloy[J].Archives of Foundry Engineering,2010,10(1):117-120.
[9]宋亮,张屹林,闫汝辉,等.基于数值模拟的铝合金活塞设计与优化[J].特种铸造及有色合金,2015,35(2):150-152.
[10]旺小霞,纵荣荣,时建松,等.发动机用铝活塞的铸造数值模拟[J].精密成型工程,2010,2(5):78-82.
[11]沈家栋,张海亮.铝合金活塞铸造工艺数值模拟研究[J].机电工程,2013,30(3):322-328.
[12]纵荣荣.金属型重力铸造铝活塞流场和温度场的数值模拟[D].合肥:合肥工业大学,2010.
[13]陈元芳,胡建军,黄虹,等.CAE技术在活塞铸造工艺设计中的应用[J].特种铸造及有色合金,2005,25(11):661-663.
[14]柳百成.铸造技术与计算机模拟发展趋势[J].铸造技术,2005,26(7):611-617.