【作者】 赵凯阳； 曾云波； 李浩如； 马薇； 林兆富； 徐慧； 舒杨； 刘波； 杨健； 唐晓亮；

【Author】 Zhao Kaiyang;Zeng Yunbo;Li Haoru;Ma Wei;Lin Zhaofu;Xu Hui;Shu Yang;Liu Bo;Yang Jian;Tang Xiaoliang;Chongqing Changan Automobile Co.,Ltd.;University of Science and Technology Beijing;Change Technology Co.,Ltd.;

【机构】 重庆长安汽车股份有限公司； 北京科技大学； 辰致科技有限公司；

【摘要】 超大型一体压铸技术是新能源汽车轻量化的革命性技术。但由于工艺复杂性和壁厚不均匀,导致超大型复杂薄壁一体压铸铝合金汽车车身结构件工艺缺陷放大,进料端和远端力学性能差异大,从而引起铆接部位易开裂。本研究借助铸造CAE仿真软件MAGMA,通过X光、工业CT、金相、SEM等检测手段,对一体化压铸过程进行全方位分析。针对某一体化大型铝合金压铸件局部自冲铆接(SPR)区域出现的开裂缺陷,探究其产生的原因及机理。随后,分别从压铸工艺、模具结构、喷涂工艺等方面进行优化。仿真与实验结果表明,压射速度、渣包体积及喷涂量对SPR区域出现的开裂缺陷的影响显著。改进方案实施后,SPR开裂现象消除,大大提高了一体化压铸件的良品率。这也为一体化大型铝合金压铸件的缺陷改善提供了参考思路。更多还原

【Abstract】 The ultra-large integrated die-casting technology is a revolutionary technology for the lightweight of new energy vehicles.However,due to the complexity of the process and the uneven wall thickness,the process defects of the super-large and complex thin-walled integrated die-casting aluminum alloy automobile body structural parts are amplified,and the mechanical properties of the feed end and the distal end are greatly different,which causes the riveting area to crack easily.In this study,with the help of casting CAE simulation software MAGMA,X-ray,industrial CT,metallographic,SEM and other detection methods were used to analyze the integrated die-casting process in an all-round way.Aiming at the cracking defects in the local self-piercing riveting (SPR)area of an integrated large-scale aluminum alloy die casting part,the causes and mechanisms of their occurrence were explored.Subsequently,the die-casting process,mold structure,spraying process and other aspects were optimized.The simulation and experimental results show that the injection velocity,slag bag volume and spraying amount significantly influence the cracking defects in the SPR area.The SPR cracking phenomenon is eliminated after the implementation of the optimization plan,which greatly improves the yield rate of integrated die castings.This also provides a reference idea for the defect improvement of integrated large-scale aluminum alloy die castings.更多还原