【作者】 陈阳；

【导师】 叶升平；

【作者基本信息】 华中科技大学 ， 材料加工工程， 2005， 硕士

【摘要】 与传统的铸造技术相比,消失模铸造技术具有无与伦比的优势。本文针对复杂铝合金玻璃检具毛坯的设计和制造,对其铸造工艺、合金成分、缺陷展开了研究。利用UG CAD/CAM 曲面造型的优势和辅助制造的功能,对检具进行三维设计,提高了设计效率,保证了检具曲面段毛坯的铸造精度,减少了加工余量。提出了基于数控加工泡沫原型的玻璃检具毛坯的快速制造工艺路线。工艺路线:3D 检具→3D 检具毛坯→3D 分块设计→检具泡沫原型的分块制造→检具泡沫原型装配、检验→消失模铸造。并着重比较了两种基于泡沫原型的检具毛坯的翻制工艺:一种是采用潮模砂消失模铸造工艺进行翻制,另一种就是采用干砂负压消失模铸造工艺进行翻制。对常用的ZL102 铝合金和新型ZAlZn5Cu2MgSi 铝合金进行了试验,新型铝合金具有强度高、机加性能好、强度适当、铸造性能好等优点。针对铸造中出现的气孔等缺陷,从合金成分、精炼条件等方面进行了分析,并提出了解决方案。利用潮模砂消失模铸造工艺,合金材料选用新型铝合金,实现了几款新车型整套玻璃检具毛坯的快速制造,包括前挡、后挡、门窗、天窗等。更多还原

【Abstract】 Lost foam casting has been regarded as a cost-effective, environment-friendly vital option to the conventional casting process for production of near-net shape castings with high quality. Aiming to the manufacturing of the automobile glass checking tools, the casting technology and the porosity defect of the checking tools were researched in this paper. With the advantage in complex face and aided manufacturing, designing and manufacturing of the checking tools took advantage of UG CAD/CAM adequately. Not only advance the precision of checking tools face, but also shorten the production cycle and decrease the manufacturing workload. Rapid manufacturing process of automobile glass checking tools roughcast based on NC machined foam prototype was brought forward. Design step: the checking tools design of three dimension→roughcast design→separate design→separate manufacture→assembly 、verification→casting. Two casting technology with different chemical composition (ZL102 & a naval Aluminum-alloy) for checking tools roughcast based on foam prototype were comparing. One is the green sands lost foam casting process, and the other is the underpressure lost foam casting process. Several main parameters including casting performance、processing performance、intensity and rigidity were tested. The application of green sands lost foam casting process and novel Aluminum-alloy to several series of roughcast manufacturing of auto glass checking tools was presented primarily. The checking tools include front shield、back shield、door window、clearstory and so on. chemical composition、purified condition pouring temperature vacuum value had apparent relationship the defects in casting. In the paper, it is analysed that the effect of these parameters on the formation of the defects, and the solutions were presented.更多还原