【作者】 马秋；

【导师】 于彦东；

【作者基本信息】 哈尔滨理工大学 ， 材料加工工程， 2005， 硕士

【摘要】 本文从国内镁合金压铸模CAD/CAE 技术与国际先进技术水平的差距和急需解决的问题着手,提出了镁合金压铸模集成CAD/CAE 的思想,并结合实际压铸模具设计的范例,实现了典型镁合金压铸件换档壳体压铸模CAD/CAE 的集成。本文重点进行了镁合金汽车零件压铸模CAE 实现的研究和标准模架库的建立。首先,针对镁合金压铸工艺特点和充型过程的不透明性,采用Pro/E 进行铸件的实体造型,并生成面网格文件。其次,利用仿真软件ProCAST 对镁合金汽车换档壳体充型过程的物理场进行模拟和仿真。通过对铸件充型模拟,分析结果表明利用压铸技术生产镁合金汽车换档壳体时,铸件中的主要缺陷为气孔和缩松。气孔的形成主要是由于在充型过程中,气体不能顺利的排出型腔,被高压的合金液卷入,挤压在铸件中,在冷却过程中汇集成气孔。这些缺陷的存在使得材料的力学性能下降,同时气密性也变差。最后,依据充型模拟分析的结果对浇注系统和溢流系统提出修正方案,再进行建模和模拟,从而得到优化工艺方案,结果表明优化的工艺方案充型效果比较理想,零件整体质量有了很大的提高。通过对汽车零件充型过程模拟说明了计算机仿真技术对真实铸造情况的再现能力强,对压铸模具设计具有很好的指导意义。另外,本文在Pro/E 及其相关功能的基础上,分析了压铸模标准模架的特征共性及标准架库的层次结构,构建了三维压铸模标准架库。设计实例表明该标准模架库对提高压铸模具设计效率有很好的实用性。更多还原

【Abstract】 After analyzing the distance between domestic die-casting mold CAD/CAE techniques and the world﹐s most advanced ones ,and problems demanding prompt solution in this field, the author suggests an idea of integrated die-casting mold CAD/CAE, and wants to practice the idea for a typical die-casting part-Shell-Gear-Change-Lever with actual example. The research is mainly on the realization of Shell-Gear-Change-Lever’s die-casting mold CAE and the establishment of standard mould bases. First, according to the specific solidification property of magnesium alloys and the opacity of the metal mould, the solid feature and the surface mesh of the magnesium die casting was made through the Pro/E. ProCAST was used to simulate physical properties of the Shell-Gear-Change-Lever’s mold filling process. The corresponding results show that the mainly defects during casting are air holes and shrinkage with using die-casting techniques to manufacture the Shell-Gear-Change-Lever. The formation of air holes could be attributed to that the air could not be successfully discharged from the die. Thus, the air is engulfed and extruded into the casting by the alloy melt with high pressure and flowing speed,then the air inside casting congregates and finally becomes the air holes. The appearance of the air holes would lead to the decrease in mechanical properties and gas tightness of Shell-Gear-Change-Lever. Modified projects of gating systems and flooding systems for die-casting mold were proposed according to the simulation result. The related models were rebuilt and the simulation was carried out again. The optimum project was achieved. The result shows that a great improvement can be achieved and the quality of the Shell-Gear-Change-Lever. This implies that the computer simulation techniques possess a satisfactory capability of reproducing the actual die-casting process and significance in guiding die-casting process design. Based on the Pro/E and its relative functions , an analysis was made to abstract the common characteristics of the standard mould bases of die-casting moulds and make clear the structure of the standard mould-base database. A 3D database of the standard mould bases of die-casting moulds was established. An example of mould design illustrated the standard mould-base database has very well practicability when the database was used in the design of die-casting moulds.更多还原