ZM5合金齿轮壳体铸造工艺研究
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摘要
以ZM5合金齿轮壳体为研究对象,通过对其结构分析以及ProCAST数值模拟,对其铸造工艺进行了研究。结果表明,对于壁厚为15~25mm,轮廓尺寸为160mm×100mm×80mm的齿轮箱壳体,采用700℃浇注,浇注时间为6s,设置2个缝隙内浇道的浇注方案能够成形良好,但是在厚凸台内部会产生缩松缺陷,实际浇注结果和模拟结果符合良好。根据ProCAST模拟结果和浇注试样的情况,对铸造工艺进行优化,改用陶瓷过滤网、增加局部冷铁、提高浇注温度后,效果良好,其化学成分、力学性能、尺寸精度、内部质量均能满足设计指标。
The effects of processing parameters on the ZM5 gear shell were investigated by product structural analysis and ProCAST simulation.The results reveal that the gear shell with the thickness of 15~25 mm and overall dimensions of 160 mm×100 mm×80 mm,can be well produced with pouring at 700℃for 6 sand setting two slit gate.However,porosity can be found in the concave position at thick wall of castings.According to the simulation results of proCAST and the actual production,the defects were obviously reduced by optimizing the casting process,such as adopting ceramic fiter,adding partial chill and increasing the pouring temperature.The chemical composition,mechanical properties,dimensional accuracy can all meet the product standard.
The effects of processing parameters on the ZM5 gear shell were investigated by product structural analysis and ProCAST simulation.The results reveal that the gear shell with the thickness of 15~25 mm and overall dimensions of 160 mm×100 mm×80 mm,can be well produced with pouring at 700℃for 6 sand setting two slit gate.However,porosity can be found in the concave position at thick wall of castings.According to the simulation results of proCAST and the actual production,the defects were obviously reduced by optimizing the casting process,such as adopting ceramic fiter,adding partial chill and increasing the pouring temperature.The chemical composition,mechanical properties,dimensional accuracy can all meet the product standard.
引文
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[3]丁佳伟,许红雨,王鑫,等.AZ91D镁合金屑制备半固态坯料的均匀性及组织演变[J].特种铸造及有色合金,2017,37(1):52-56.
[4]王悬悬,谷鹏.热处理对汽车用AZ31镁合金组织性能的影响[J].热加工工艺,2016(18):170-172.
[5]陈淑英,陈智麟,邵秉川,等.熔体过热处理对AZ91D镁合金组织与性能的影响[J].稀有金属材料与工程,2016(6):1 620-1 624.
[6]黄曼青,周全,刘峰,等.直流磁场对AZ91D镁合金凝固组织和力学性能的影响[J].特种铸造及有色合金,2016,36(3):320-323.
[7]陈旭,蒋文明,王本京,等.机械振动对消失模-熔模铸造AZ91D镁合金组织的影响[J].特种铸造及有色合金,2016,36(2):186-191.
[8]李明月,刘海峰,崔晓鹏.镁合金坐盆铸件显微组织与性能差异研究[J].铸造,2017,66(7):686-690.
[9]刘晓晶,唐先林,李官,等.大高径比铝镁合金筒形件成形工艺的数值模拟[J].特种铸造及有色合金,2016,36(8):796-799.
[10]娄大光.大型薄壁镁合金支架铸件的低压铸造工艺研究[D].哈尔滨:哈尔滨工业大学,2015.
[11]董丽波,刘传宝,张勇,等.镁合金机匣盖铸件流线缺陷控制的数值模拟[J].特种铸造及有色合金,2015,35(1):23-25.
[12] CHEN Y A,JIN L,FANG D,et al.Effects of calcium,samarium addition on microstructure and mechanical properties of AZ61magnesium alloy[J].Journal of Rare Earths,2015(1):86-92.
[13] HUANG H,FU P H,WANG Y X,et al.Effect of pouring and mould temperature on hot tearing susceptibility of AZ91D and Mg-3Nd-0.2Zn-Zr Mg alloys[J].Transactions of Nonferrous Metals Society of China,2014,24(4):922-929.
[14] CHENG Y L,QIN T W,WANG H M,et al.Comparison of corrosion behaviors of AZ31,AZ91,AM60and ZK60magnesium alloys[J].Transactions of Nonferrous Metals Society of China,2009(3):517-524.