汽车安全带旋转芯轴压铸件的充型模拟及模具设计
|
摘要
压力铸造具有生产效率高,压铸件尺寸精度高,组织致密,具有较高的强度和硬度等优点,广泛的运用于工业生产之中。压铸模具在整个压铸生产中占有重要的地位。传统的压铸模具设计过程存在着过多的依赖于模具工程师的个人经验,模具设计的周期较长,设计工作繁重等缺点。
压铸的充型过程对压铸件的质量有着重要的影响。压铸件中许多缺陷都是由于充型过程不平稳造成的。压铸模具的浇注系统和溢流槽的设计合理与否很大程度上决定着压铸充型过程是否平稳。本文开始先根据作者的经验设计了一个汽车安全带旋转芯轴压铸模具的浇注系统和溢流槽的工艺方案。引入铸造数值模拟软件Pro/CAST对汽车安全带旋转芯轴压铸件的充型过程进行模拟,发现充型过程平稳,但是在压铸件的两端发现了缩松缺陷。针对这个问题,作者在原工艺方案的基础之上在压铸件的两端分别增设了一个溢流槽。再用Pro/CAST观察充型过程是整个充型过程。发现充型过程平稳,缩松缺陷被转移到增设的溢流槽中去了,通过后续加工,可以将缩松的部位切除。达到了对压铸件的质量要求。
在完成浇注系统和溢流槽的优化设计的基础之上,用Pro/Engineer2.0模具设计模块完成压铸模具型腔和斜滑块抽芯机构的设计。传统的压铸模具设计是在完成模具型腔的设计后,直接在二维设计软件里完成模架的设计,这种设计方法具有劳动强度大、设计不直观、设计周期比较长等缺点,本文通过模架专家系统EMX4.1的引入,直接在EMX4.1里三维地添加模架降低了设计的的强度,缩短了模架设计的周期,增强了模架设计的直观性。
本文通过引入数值模拟软件Pro/CAST对汽车安全带旋转芯轴压铸件充型过程进行模拟,优化浇注系统和溢流槽的设计,指导了作者的模具设计过程。通过Pro/Engineer2.0模具设计模块完成模具的型腔设计和斜滑块抽芯机构的设计,通过模架专家系统EMX4.1的引入完成了模具的模架设计,缩短了模架设计的周期,通过以上的运用充分体现了CAD/CAE技术对压铸模具设计的提升作用。
With the features of high productivity, high dimensional accuracy, and high strength and hardness due to its dense structure, die casting is being widely applied in industrial production. The die casting mold plays an important role in die-casting production, however, the traditional die-casting mold design process has the following disadvantages of excessive dependence upon the mold engineer’s personal experience, a too long mold designing cycle and a heavy designing work-load.
The filling process of die-casting has a significant impact on quality of die casting. Many defects are due to the unstability in filling process. Whether the design of gating system and overflow tank of die casting mould is reasonable to a large extent determines wheter the filling process is stable or not.This paper is started with a gating system and overflow tank technology program of a vehicle seat belt spin spindle designed based on the author’s experience,then the filling process of the technology program is simulated through the introduction of the numerical simulation software Pro/CAST.It turns out that the filling process is stable, but dispersed shrinkage is found at the two ends of the die casting. In order to solve the problem, an overflow tank is added to each of the two ends of the die casting. In a repeated simulation filling process course, the improved one turns out that the filling process is stable, and dispersed shrinkage is transferred to the newly added overflow tanks, which can be removed through later process, reaching the quality requirements of die casting.
After finishing the optimisation design of the gating system and overflow tank, Pro/Engineer 2.0 module is used to complete the design of die cavity and core-pulling mechanism with a slide. In the traditional die-casting mold design process, the design of moldbase is completed in 2D design software after the design of die cavity. This method bears the following disadvantages such as labour intensity, indirect viewing and relatively long design cycles. In this paper, EMX.4.1 is introduced, in which moldbase is modified from 3D view, reducing the labour-intensity of design, shortening designing cycle of moldbase and strengthing intuition.
Through the introduction of numerical simulation software Pro/CAST to simulate the filling process of vehicle seat belt spin spindle in this paper, the design of gating system and overflow tank is optimised and the design process of the author’s moldbase is guided. designing cycle of mold base is shortened by applying Pro / Engineer 2.0 module to complete the design of die cavity and core-pulling mechanism with a slide and EMX.4.1 to complete the design of moldbase of die-casting mold, which fully embodies the promotion of CAD/CAE technology on the design of die-casting mold.
压铸的充型过程对压铸件的质量有着重要的影响。压铸件中许多缺陷都是由于充型过程不平稳造成的。压铸模具的浇注系统和溢流槽的设计合理与否很大程度上决定着压铸充型过程是否平稳。本文开始先根据作者的经验设计了一个汽车安全带旋转芯轴压铸模具的浇注系统和溢流槽的工艺方案。引入铸造数值模拟软件Pro/CAST对汽车安全带旋转芯轴压铸件的充型过程进行模拟,发现充型过程平稳,但是在压铸件的两端发现了缩松缺陷。针对这个问题,作者在原工艺方案的基础之上在压铸件的两端分别增设了一个溢流槽。再用Pro/CAST观察充型过程是整个充型过程。发现充型过程平稳,缩松缺陷被转移到增设的溢流槽中去了,通过后续加工,可以将缩松的部位切除。达到了对压铸件的质量要求。
在完成浇注系统和溢流槽的优化设计的基础之上,用Pro/Engineer2.0模具设计模块完成压铸模具型腔和斜滑块抽芯机构的设计。传统的压铸模具设计是在完成模具型腔的设计后,直接在二维设计软件里完成模架的设计,这种设计方法具有劳动强度大、设计不直观、设计周期比较长等缺点,本文通过模架专家系统EMX4.1的引入,直接在EMX4.1里三维地添加模架降低了设计的的强度,缩短了模架设计的周期,增强了模架设计的直观性。
本文通过引入数值模拟软件Pro/CAST对汽车安全带旋转芯轴压铸件充型过程进行模拟,优化浇注系统和溢流槽的设计,指导了作者的模具设计过程。通过Pro/Engineer2.0模具设计模块完成模具的型腔设计和斜滑块抽芯机构的设计,通过模架专家系统EMX4.1的引入完成了模具的模架设计,缩短了模架设计的周期,通过以上的运用充分体现了CAD/CAE技术对压铸模具设计的提升作用。
With the features of high productivity, high dimensional accuracy, and high strength and hardness due to its dense structure, die casting is being widely applied in industrial production. The die casting mold plays an important role in die-casting production, however, the traditional die-casting mold design process has the following disadvantages of excessive dependence upon the mold engineer’s personal experience, a too long mold designing cycle and a heavy designing work-load.
The filling process of die-casting has a significant impact on quality of die casting. Many defects are due to the unstability in filling process. Whether the design of gating system and overflow tank of die casting mould is reasonable to a large extent determines wheter the filling process is stable or not.This paper is started with a gating system and overflow tank technology program of a vehicle seat belt spin spindle designed based on the author’s experience,then the filling process of the technology program is simulated through the introduction of the numerical simulation software Pro/CAST.It turns out that the filling process is stable, but dispersed shrinkage is found at the two ends of the die casting. In order to solve the problem, an overflow tank is added to each of the two ends of the die casting. In a repeated simulation filling process course, the improved one turns out that the filling process is stable, and dispersed shrinkage is transferred to the newly added overflow tanks, which can be removed through later process, reaching the quality requirements of die casting.
After finishing the optimisation design of the gating system and overflow tank, Pro/Engineer 2.0 module is used to complete the design of die cavity and core-pulling mechanism with a slide. In the traditional die-casting mold design process, the design of moldbase is completed in 2D design software after the design of die cavity. This method bears the following disadvantages such as labour intensity, indirect viewing and relatively long design cycles. In this paper, EMX.4.1 is introduced, in which moldbase is modified from 3D view, reducing the labour-intensity of design, shortening designing cycle of moldbase and strengthing intuition.
Through the introduction of numerical simulation software Pro/CAST to simulate the filling process of vehicle seat belt spin spindle in this paper, the design of gating system and overflow tank is optimised and the design process of the author’s moldbase is guided. designing cycle of mold base is shortened by applying Pro / Engineer 2.0 module to complete the design of die cavity and core-pulling mechanism with a slide and EMX.4.1 to complete the design of moldbase of die-casting mold, which fully embodies the promotion of CAD/CAE technology on the design of die-casting mold.
引文
[1]黄荣学,范洪远.我国模具工业发展概述及展望[J].机械工程师,2008,(5):13-15.
[2]袁种璘.模具标准件的发展趋势及需要解决的问题[J].模具制造,2006,(6) :1-2.
[3]郑涌.模具行业现状及其发展趋势[J].机械与电子.2008,(4):64-65.
[4] Chipley K,Viswanathan S ,Copper R H. Concurrent Engineering and Rapid Prototyping for Die Castings. Die Casting Engineer ,1996,(3) :18-26.
[5]陈光明.压铸模CAD/CAE/CAM的研究现状和发展.铸造技术[J],2004,25(2):148-149.
[6]申长雨.塑料注射模具计算机辅助工程[M].郑州:河南科技出版社,1998.
[7]吴崇峰.实用注塑模CAD/CAE/CAM技术[M].北京:中国轻工业出版社,2000.
[8]王国中.注塑模CAD/CAE/CAM技术[M].北京:北京理工出版社,1999.
[9]张先波,吕志刚.压铸模CAD概况[J].机械工艺师,1995 ,(8) :31-32.
[10]王贵,宰守宾,贺冰.铝合金压铸件充型和凝固过程的数值模拟[J].铸造技术,1998, (2) :44-46.
[11]陈立亮.低压铸造连续生产过程数值模拟及其质量控制[D].武汉:华中科技大学,1997.
[12]杨宠,林汉同,刘瑞祥.我国压铸模CAD/CAE/CAM及其一体化技术[J] .特种铸造及有色金属,2002,(1):20-21.
[13]黄引平,马敏团,郝炜,田永维.大型复杂铸件CAD/CAE工程优化实践.铸造,2006,55(12):1255-1259.
[14]唐婕,范洪远,习燕,黄荣学.基于Pro/E的压铸模CAD技术[J],机械工程师,2005,(5):90-91.
[15] Zhang Weishan,Xiong Shoumei,Liu Baicheng.Study on a CAD/CAE/CAM system of die-casting[J].Journal of materials processing technology,1997,(63):707-711.
[16] Davey K,Bound S.Modeling the pressure die casting process using boundary and finite element methods[J],Mater.process Technol,1996,63(1-3):696-700.
[17] Saunders N , L I X ,Miodownik A P , et al . Proceedings of the conference liquid metal processing 2003 nancy [ C ] . France ,2003,9:21-24.
[18] Rigau T C. Simulator a 3-D modeller software for casting mold filling and metal solidification [ J ] . Hommers Et fonderie , 1990,(10) :18-23.
[19] Sulaiman S,Hamouda AMS,Abedin S,et al . Simulation of metal filling progress during the casting process[J ] . Journal of Materials Processing Technology ,2000 ,100 (8) :224-229.
[20] Xiong M , Liu B C ,J IA L G. Study on numerical simulation of mold filling and solidificationprocesses under pressure condition[J ] . J . Mater . Technol,2002, (5) :413-416.
[21] Xiong M,Lau F,Lee WB. An efficient thermal analysis system for the die casting process [ J ] . Journal of Materials Processing Technology , 2002 ,(128) :19-24.
[22] Xiong S M , Lau F ,Lee WB , et al . Numerical methods to improve the computational efficiency of thermal analysis for t he die-casting process [J ] . Journal of Materials Processing Technology ,2003 ,(139):457-461.
[23] Wang W M ,Li D Y, Peng Y H , et al . Simulation analysis of cooling capacity in mold during LPDC of magnesium wheel [ J ] .Shanghai Jiaotong Daxue Xuebao/ Journal of Shanghai Jiaotong University ,2005 ,39 (7) :1 082-1 085.
[24]李仁杰.压力铸造技术[M].北京:国防工业出版社,1996,(7):5-6.
[25] Kim E S , Lee K H , Moon Y H. A Feasibility Study of the Partial Squeeze and Vacuum Die Casting Process. Journal of Materials Processing . Technology ,2000 ,(105) :42-48 .
[26] J. C. Lin. Selection of the Optimal Gate Location for a Die-Casting Die with a Freeform Surface[J]. Advanced Manufacturing Technology,2002(19):278-284.
[27]骆枏生,许琳主编.金属压铸工艺与模具设计.北京:清华大学出版社.2006.7.9-10.
[28]林清安.模具设计[M].北京:电子工业出版社.2005.4.1.
[29]郑景懋.专家模架系统EMX[J].软件世界.2004,5:56-48.
[30]马敏团,陈鹏波,黄引平,王伟. ProCAST在铸造工艺优化中的应用[J].热加工工艺.2006,35(1):52-57.
[31]潘宪曾主编.压铸模设计手册.第三版.北京:机械工业出版社.2006.7.60.
[32]李仁杰.压力铸造技术[M].北京:国防工业出版社,1996.7.128.
[33]骆枏生,许琳主编.金属压铸工艺与模具设计.北京:清华大学出版社.2006.7.78.
[34]李仁杰.压力铸造技术[M].北京:国防工业出版社,1996.1-2.
[35]杨世铭,陶文铨.传热学.第三版.高等教育出版社,2003:28-32.
[36]贾良荣,熊守美.压力铸造充型过程流动与传热数值模拟的研究.清华大学学报(自然科学版),2001,41(2):8-11.
[37]潘宪曾.压铸模具设计手册[M].北京:机械工业出版社,1998.10.98.
[38]骆枏生,许琳.金属压铸工艺与模具设计[M].北京:清华大学出版社,2006.7.104.
[39]王明强,朱永梅,刘文欣。有限元玩网格划分方法应用研究[J]。机械设计与制造,2004.
[40]周玉辉,吴卫,周华彬.工艺参数与模具结构对压铸模具温度的影响[J].铸造技术,2006,27(6):570-573.
[41]韩雄伟,吴卫.铝合金压铸模具温度场数值分析[J].常熟理工学院学报(自然科学版),2007,21(4):80-83.
[42] A. Hamasaiid, G. Dour, M.S. Dargusch, T. Loulou, C. Davidson,and G. Savage.Heat-Transfer Coefficient and In-Cavity Pressure at the Casting-Die Interface during High-Pressure Die Casting of the Magnesium Alloy AZ91D [J].Metallurgical and Materials Transactions,2008,4(39): 853-863.
[43]骆枏生,许琳.金属压铸工艺与模具设计[M].北京:清华大学出版社,2006.7.104.
[44]潘宪曾.压铸模具设计手册[M].北京:机械工业出版社,1998.10.138.
[45]潘宪曾.压铸模具设计手册[M].北京:机械工业出版社,1998.10. 237-264.
[2]袁种璘.模具标准件的发展趋势及需要解决的问题[J].模具制造,2006,(6) :1-2.
[3]郑涌.模具行业现状及其发展趋势[J].机械与电子.2008,(4):64-65.
[4] Chipley K,Viswanathan S ,Copper R H. Concurrent Engineering and Rapid Prototyping for Die Castings. Die Casting Engineer ,1996,(3) :18-26.
[5]陈光明.压铸模CAD/CAE/CAM的研究现状和发展.铸造技术[J],2004,25(2):148-149.
[6]申长雨.塑料注射模具计算机辅助工程[M].郑州:河南科技出版社,1998.
[7]吴崇峰.实用注塑模CAD/CAE/CAM技术[M].北京:中国轻工业出版社,2000.
[8]王国中.注塑模CAD/CAE/CAM技术[M].北京:北京理工出版社,1999.
[9]张先波,吕志刚.压铸模CAD概况[J].机械工艺师,1995 ,(8) :31-32.
[10]王贵,宰守宾,贺冰.铝合金压铸件充型和凝固过程的数值模拟[J].铸造技术,1998, (2) :44-46.
[11]陈立亮.低压铸造连续生产过程数值模拟及其质量控制[D].武汉:华中科技大学,1997.
[12]杨宠,林汉同,刘瑞祥.我国压铸模CAD/CAE/CAM及其一体化技术[J] .特种铸造及有色金属,2002,(1):20-21.
[13]黄引平,马敏团,郝炜,田永维.大型复杂铸件CAD/CAE工程优化实践.铸造,2006,55(12):1255-1259.
[14]唐婕,范洪远,习燕,黄荣学.基于Pro/E的压铸模CAD技术[J],机械工程师,2005,(5):90-91.
[15] Zhang Weishan,Xiong Shoumei,Liu Baicheng.Study on a CAD/CAE/CAM system of die-casting[J].Journal of materials processing technology,1997,(63):707-711.
[16] Davey K,Bound S.Modeling the pressure die casting process using boundary and finite element methods[J],Mater.process Technol,1996,63(1-3):696-700.
[17] Saunders N , L I X ,Miodownik A P , et al . Proceedings of the conference liquid metal processing 2003 nancy [ C ] . France ,2003,9:21-24.
[18] Rigau T C. Simulator a 3-D modeller software for casting mold filling and metal solidification [ J ] . Hommers Et fonderie , 1990,(10) :18-23.
[19] Sulaiman S,Hamouda AMS,Abedin S,et al . Simulation of metal filling progress during the casting process[J ] . Journal of Materials Processing Technology ,2000 ,100 (8) :224-229.
[20] Xiong M , Liu B C ,J IA L G. Study on numerical simulation of mold filling and solidificationprocesses under pressure condition[J ] . J . Mater . Technol,2002, (5) :413-416.
[21] Xiong M,Lau F,Lee WB. An efficient thermal analysis system for the die casting process [ J ] . Journal of Materials Processing Technology , 2002 ,(128) :19-24.
[22] Xiong S M , Lau F ,Lee WB , et al . Numerical methods to improve the computational efficiency of thermal analysis for t he die-casting process [J ] . Journal of Materials Processing Technology ,2003 ,(139):457-461.
[23] Wang W M ,Li D Y, Peng Y H , et al . Simulation analysis of cooling capacity in mold during LPDC of magnesium wheel [ J ] .Shanghai Jiaotong Daxue Xuebao/ Journal of Shanghai Jiaotong University ,2005 ,39 (7) :1 082-1 085.
[24]李仁杰.压力铸造技术[M].北京:国防工业出版社,1996,(7):5-6.
[25] Kim E S , Lee K H , Moon Y H. A Feasibility Study of the Partial Squeeze and Vacuum Die Casting Process. Journal of Materials Processing . Technology ,2000 ,(105) :42-48 .
[26] J. C. Lin. Selection of the Optimal Gate Location for a Die-Casting Die with a Freeform Surface[J]. Advanced Manufacturing Technology,2002(19):278-284.
[27]骆枏生,许琳主编.金属压铸工艺与模具设计.北京:清华大学出版社.2006.7.9-10.
[28]林清安.模具设计[M].北京:电子工业出版社.2005.4.1.
[29]郑景懋.专家模架系统EMX[J].软件世界.2004,5:56-48.
[30]马敏团,陈鹏波,黄引平,王伟. ProCAST在铸造工艺优化中的应用[J].热加工工艺.2006,35(1):52-57.
[31]潘宪曾主编.压铸模设计手册.第三版.北京:机械工业出版社.2006.7.60.
[32]李仁杰.压力铸造技术[M].北京:国防工业出版社,1996.7.128.
[33]骆枏生,许琳主编.金属压铸工艺与模具设计.北京:清华大学出版社.2006.7.78.
[34]李仁杰.压力铸造技术[M].北京:国防工业出版社,1996.1-2.
[35]杨世铭,陶文铨.传热学.第三版.高等教育出版社,2003:28-32.
[36]贾良荣,熊守美.压力铸造充型过程流动与传热数值模拟的研究.清华大学学报(自然科学版),2001,41(2):8-11.
[37]潘宪曾.压铸模具设计手册[M].北京:机械工业出版社,1998.10.98.
[38]骆枏生,许琳.金属压铸工艺与模具设计[M].北京:清华大学出版社,2006.7.104.
[39]王明强,朱永梅,刘文欣。有限元玩网格划分方法应用研究[J]。机械设计与制造,2004.
[40]周玉辉,吴卫,周华彬.工艺参数与模具结构对压铸模具温度的影响[J].铸造技术,2006,27(6):570-573.
[41]韩雄伟,吴卫.铝合金压铸模具温度场数值分析[J].常熟理工学院学报(自然科学版),2007,21(4):80-83.
[42] A. Hamasaiid, G. Dour, M.S. Dargusch, T. Loulou, C. Davidson,and G. Savage.Heat-Transfer Coefficient and In-Cavity Pressure at the Casting-Die Interface during High-Pressure Die Casting of the Magnesium Alloy AZ91D [J].Metallurgical and Materials Transactions,2008,4(39): 853-863.
[43]骆枏生,许琳.金属压铸工艺与模具设计[M].北京:清华大学出版社,2006.7.104.
[44]潘宪曾.压铸模具设计手册[M].北京:机械工业出版社,1998.10.138.
[45]潘宪曾.压铸模具设计手册[M].北京:机械工业出版社,1998.10. 237-264.