【摘要】 利用Magma软件对汽车发动机支架高压压铸(HPDC)过程进行数值模拟,验证了支架缺陷类型及位置与实际生产的一致性。分析得出了其气孔缺陷较高的原因是铸件高低分型大、壁厚不均及浇口过早的凝固,导致气体难以排出,且远端无法得到压力的良好作用,故形成气孔缺陷。通过分析气孔形成原因及其位置,设计局部挤压装置,利用局部挤压工艺解决远端承载孔周围存在的气孔缺陷问题。运用射线实时成像技术进行验证,从而建立将局部挤压工艺与高压压铸及CAE相结合的发动机支架铸件生产方式,使发动机支架局部气孔率降低至0.6%,有效提高了产品品质。更多还原

【Abstract】 With the help of Magma software,the high pressure die casting process of automobile engine bracket was simulated.The results show that the bracket’s defects type and location predicted are well agreement with practical ones.The uneven part surface and thickness and gate solidification ahead result in difficulties in exhausting air,together with the poor effect of pressure at the distal end,which are responsible for generation of gas hole.Through analysis of gas hole formation and location,local squeezing device was designed to solve gas holes around the distal bearing hole,and it was observed by X-ray imaging system.Thus,the efficient engine bracket production mode combining with local squeezing process and high pressure die casting as well as CAE analysis was established,which could reduce gas hole rate in the engine bracket to 0.6%,improving effectively production efficiency.更多还原