汽车铝合金轮毂压铸过程数值模拟及工艺参数优化
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摘要
汽车铝合金轮毂具有重量轻,比强度高,耐腐蚀、加工性好等优点,在现代汽车产业得到广泛应用。本文讨论对汽车铝合金轮毂采用压铸工艺,可以在最大限度减少铸造缺陷同时,提高铸件的密度和强度。但实际生产中,铝合金轮毂压铸的工艺参数不容易确定,模具调试时间长,铸件质量不易量化控制。因此本文试图通过压铸过程数值模拟,仿真制造汽车铝合金轮毂,预测压铸过程出现的缺陷,并帮助工程师制定合理的压铸工艺参数水平。
压铸过程数值模拟是现代铸造工业的重要手段,通过模拟对铝合金轮毂进行质量预报,从而减少制订压铸工艺的盲目性,通过对工艺参数的分析研究,可以优化方案,从而确保铸件质量,提高生产效率。这也为铸造工程师提供新的途径来研究压铸过程。
本论文采用正交实验设计方法及ProCAST软件包作为压铸过程数值模拟工具,从影响汽车铝合金轮毂质量的重要铸造缺陷出发,确定影响轮毂质量的工艺参数,将每个工艺参数量化成若干水平,利用正交实验制定实验方案,模拟压铸过程充型和凝固中的流场和温度场,并根据这些物理场对铸件质量进行选择和确定压铸工艺参数。
本文最大的特点是将各压铸缺陷进行独立量化的正交实验极差分析和方差分析,通过这些分析可知各工艺参数对此铸造缺陷的影响权重,然后综合考虑各铸造缺陷对轮毂铸件整体质量的影响权重,权衡和舍取工艺参数的水平,以达到铸件整体质量的最优化。
由正交试验设计分析求得的最佳生产工艺参数组合为:浇注温度600℃、浇注速度45m/s,模具温度180℃。此组参数可减少裹气、氧化夹杂、缩松缩孔等铸造缺陷,并缩短压铸单位生产周期。通过生产实际对比,模拟结果与实际生产情况基本相符。对同类产品的生产过程,确定最优工艺参数、合理设计模具和提高产品质量等均具有普遍的指导和参考意义。
Aluminum alloy wheel hub, which has advantages such as less density, higher strength to mass ratio, corrosion resistance and better processability etc, is widely used in automobile industry. For reducing the die casting defects in maximum and improving the density and strength, the aluminum alloy wheel hub is cast by die casting technology in this paper. In practical production, the process parameters of die casting are hard to confirm, the time to adjust casting die is too long and the quality of casting product is difficult to accurately control. Therefore this paper tries to using die casting process numerical simulation technology, to virtual manufacture the aluminum alloy automobile wheel hub, which can forecast the die casting defects and help the engineers to make reasonable level of die casting process parameter.
Die casting process simulation is an important method in modem foundry industry. It can carry out the useful forecast of the wheel hub casting quality, thus reducing the blindness in making die casting proeess; Analysis of process parameters can be optimized, thus ensuring the die casting quality and production efficiency. It also provides a new way for casting engineers to study casting foundry Process.
This paper using orthogonal experiment design method and ProCAST software baggage as the tool of die casting process numerical simulation, view in the serious defects that influence wheel hub die casting quality, to decide the casting process parameter, and divide every casting process parameter into several level, which will be used in orthogonal experiment to design the simulations about the flow field and temperature field in die casting process, and base on these simulations to choose and ensure the optimized parameter.
The biggest characteristics in this paper is using independent quantitative range analysis and variance analysis of orthogonal experiment to analyze die casting defects, base on these analysis, detect the weight of each process parameter to die casting defects, then synthetically think over the influence of whole casting quality by the weight of every die casting defect, to balance and choose the level of casting process parameter for seeking the whole quality optimization of casting.
Base on the orthogonal experiment analysis, the optimal combination of die casting process parameter is that: casting temperature 600℃, casting velocity 45m/s, die temperature 180℃. By using this combination of process parameter, can reduce the defects such as gas trapping, oxide inclusion, shrinkage cavity and porosity, and shorten the production cycle of casting. Comparing with the practical production, the result of simulation is basically same as the actual production condition.To the same kind product, this simulation and analysis is the guidance and consult to work out the optimal parameter, design reasonable die and improve the quality of casting product.
压铸过程数值模拟是现代铸造工业的重要手段,通过模拟对铝合金轮毂进行质量预报,从而减少制订压铸工艺的盲目性,通过对工艺参数的分析研究,可以优化方案,从而确保铸件质量,提高生产效率。这也为铸造工程师提供新的途径来研究压铸过程。
本论文采用正交实验设计方法及ProCAST软件包作为压铸过程数值模拟工具,从影响汽车铝合金轮毂质量的重要铸造缺陷出发,确定影响轮毂质量的工艺参数,将每个工艺参数量化成若干水平,利用正交实验制定实验方案,模拟压铸过程充型和凝固中的流场和温度场,并根据这些物理场对铸件质量进行选择和确定压铸工艺参数。
本文最大的特点是将各压铸缺陷进行独立量化的正交实验极差分析和方差分析,通过这些分析可知各工艺参数对此铸造缺陷的影响权重,然后综合考虑各铸造缺陷对轮毂铸件整体质量的影响权重,权衡和舍取工艺参数的水平,以达到铸件整体质量的最优化。
由正交试验设计分析求得的最佳生产工艺参数组合为:浇注温度600℃、浇注速度45m/s,模具温度180℃。此组参数可减少裹气、氧化夹杂、缩松缩孔等铸造缺陷,并缩短压铸单位生产周期。通过生产实际对比,模拟结果与实际生产情况基本相符。对同类产品的生产过程,确定最优工艺参数、合理设计模具和提高产品质量等均具有普遍的指导和参考意义。
Aluminum alloy wheel hub, which has advantages such as less density, higher strength to mass ratio, corrosion resistance and better processability etc, is widely used in automobile industry. For reducing the die casting defects in maximum and improving the density and strength, the aluminum alloy wheel hub is cast by die casting technology in this paper. In practical production, the process parameters of die casting are hard to confirm, the time to adjust casting die is too long and the quality of casting product is difficult to accurately control. Therefore this paper tries to using die casting process numerical simulation technology, to virtual manufacture the aluminum alloy automobile wheel hub, which can forecast the die casting defects and help the engineers to make reasonable level of die casting process parameter.
Die casting process simulation is an important method in modem foundry industry. It can carry out the useful forecast of the wheel hub casting quality, thus reducing the blindness in making die casting proeess; Analysis of process parameters can be optimized, thus ensuring the die casting quality and production efficiency. It also provides a new way for casting engineers to study casting foundry Process.
This paper using orthogonal experiment design method and ProCAST software baggage as the tool of die casting process numerical simulation, view in the serious defects that influence wheel hub die casting quality, to decide the casting process parameter, and divide every casting process parameter into several level, which will be used in orthogonal experiment to design the simulations about the flow field and temperature field in die casting process, and base on these simulations to choose and ensure the optimized parameter.
The biggest characteristics in this paper is using independent quantitative range analysis and variance analysis of orthogonal experiment to analyze die casting defects, base on these analysis, detect the weight of each process parameter to die casting defects, then synthetically think over the influence of whole casting quality by the weight of every die casting defect, to balance and choose the level of casting process parameter for seeking the whole quality optimization of casting.
Base on the orthogonal experiment analysis, the optimal combination of die casting process parameter is that: casting temperature 600℃, casting velocity 45m/s, die temperature 180℃. By using this combination of process parameter, can reduce the defects such as gas trapping, oxide inclusion, shrinkage cavity and porosity, and shorten the production cycle of casting. Comparing with the practical production, the result of simulation is basically same as the actual production condition.To the same kind product, this simulation and analysis is the guidance and consult to work out the optimal parameter, design reasonable die and improve the quality of casting product.
引文
[1]王祝堂.试论我国汽车铝合金轮毂工业的发展[J].铝加工技术,1994(1):7-13.
[2]王昕.铝合金汽车轮毂的生产方法[J].轻合金加工技术,2001(8):38-42.
[3]王毅.铝合金车轮在汽车上的应用效果[J].客车技术与研究,2002,5(24):37-38
[4]蒋鹏.铸造锻造技术在铝合金轮毂成形中的应用[J].汽车工艺与材料,1999(5):1-3
[5]于铭.铝制车轮[J].当代汽车,1991(3):39-42
[6]柳百成,荆涛.铸造工程的模拟仿真与质量控制[M].北京:机械工业出版社,2001.
[7]周业明,李莉,胡志男等.铸造有限元模拟预测铸钢件的宏观缩孔缺陷[J].铸造,2001.
[8]赖华清.压铸工艺及模具[M].北京:机械工业出版社,2004
[9]潘宪曾.压铸模设计手册(第2版)[M].北京:机械工业出版社,1999
[10]张希俊,张方,张红松.铸造过程计算机数值模拟的国内外研究概况[J].昆明理工大学学报,2003(2):55-58
[11]林毅.压铸模CAE分析及并行设计技术的工程应用[J].模具制造,2002(6):10-12
[12]柳百成,康进武.铸件凝固过程的宏观及微观计算机模拟研究[J].铸造工程.造型材料,2000,24(3):1-6
[13]Shoumei XIONG,Baicheng LIU,Liangrong JIA.Study on Numerical Simulation of Mold Filling and Solidfiieation Proeesses under Perssure Conditio[J].J.Mater.Sci.Technol.2002(5):413-416
[14]帕坦卡S V.传热与流体流动的数值计算[M].科学出版社,1984
[15]李嘉荣,钟振纲.计算机技术在铸造中的应用现状与发展趋势[J].材料工程,1996(11):3-8
[16]Bastain K.M..A Look Back at the 20th Century Casting Process Simulation[J].Moden Casting,2000(12):43-45
[17]Hirt C.W.,Nichols B.D..Volume of Fluid Method for the Dynamics of Free Boundaries[J].Comp Phys,1981,39:201-225
[18]AL Rawahji N.Numerical Simulation of Dendritiesolidification with Convection:Three dimensional Flow[J].Journal of Computational Physies,2004,194:677-696
[19]陈梅清.铸件凝固过程数值模拟[M].重庆.重庆大学出版社.1991
[20]大中逸雄.计算机传热凝固解析入门[M].北京.机械工业出版社.1998
[21]张世辉.铸件凝固过程数值模拟软件在生产中的应用[J].铸造,1999.5
[22]蒋玉明.件凝固模拟和铸造工艺CAD的发展[J].都科技大学学报.1994.1-2
[23]柳百成.铸件充型凝固过程数值模拟国内外研究进展[J].铸造,1998(8):40-43
[24]林国荣.铸件形成过程计算机数值模拟的发展及应用[J].现代铸铁,2001(2):8-9
[25]李梅娥,邢建东.铸造应力场数值模拟的研究进展[J].铸造,2002,51(3):141-143
[26]张世辉,周佩超,吴振超.铸件凝固过程计算机数值模拟软件在生产中的应用[J].铸造,1999(5):18-20
[27]Si H.M..A Hybrid Method forCasing Proeess Simulation by combining FDM and FEM with an Effieient Data Conversion Algorithm[J].Materials Proeessing Teehnology,2003,133:311-321
[28]Zhang H,Wang X Y,Zheng L L.Numerical Simulation of Nueleation,Solidifieation and Mierostrueture Formation in Thermal Spraying[J].International Journal of Heat and Mass Transfer,2004,47:2191-2203
[29]许庆彦,柳百成.铸造合金凝固组织的计算机模拟与预测[J].稀有金属材料与工程,2003,32(6):401-405.
[30]Midea T.Process Simulation Software Round-up[J].ModernCasing,2002,90(8):40-45
[31]周丹晨,蒋玉明,杨屹.国外铸件充型凝固过程数值模拟软件介绍[J].热加工工艺,2000(5):45-46
[32]王金华.铸件结构设计[M].北京.机械工业出版社,1983.7-24
[33]王喜军.铸件充型与凝固过程数值模拟集成软件系统的研究[D].哈尔滨工业大学工学硕士学位论文,1998.05
[34]李世宁.大型薄壁铸件充型过程数值模拟.哈尔滨工业大学硕士学位论文,2002.05
[35]Barkhudarov M.Simulation of surface Turbulence Fluid Phenomena.During Mold Filling AFS Transactions.1995.
[36]麻向军,阳晓军.垂直缝隙式浇注系统充型特性的数值模拟[J].机械研究与应用,2004(4):33-34
[37]美国通力(UFC)有限公司.ProCAST培训简要教程
[38]杨亚杰.铸造模拟软件ProCAST[J].CAD/CAM与制造业信息化,2004,Zl
[39]刑涛 凝固过程数值模拟[M].北京.电子工业出版社2003
[40]胡红军.ProCAST软件的特点及其在铸件成形过程中的应用[J].热加工工艺,2005,(1):70-71.
[41]Electronic Data System Corporation,Unigraphics Division.UG/CAD User Guide.2001
[42]林清安编著.Pro/ENGINEER20001模具设计,北京大学出版社
[43]黄圣杰,张盖三,洪立群编著.Pro/ENGINEER2001高级开发实例.北京:电子工业出版社,2002.2
[44]ESI.ProCAST User Manual[M].2007
[45]于百库等.Pro/E与ProCAST接口方式的探讨[J].中国铸造装备与技术.2002,1
[46]杨亚杰.铸造模拟软件ProCAST[J].CAD/CAM与制造业信息化,2004年21期
[46]杨亚杰.铸造模拟软件ProCAST[J].CAD/CAM与制造业信息化,2004年21期
[47]吴春苗.压铸实用技术.广州:广东科技出版社,2003
[48]压铸模具设计手册编写组.压铸模设计手册.北京:机械工业出版社,1981,
[49]潘复生,张丁飞等.铝合金及应用.北京:化学工业出版社,2006.57-97.
[2]王昕.铝合金汽车轮毂的生产方法[J].轻合金加工技术,2001(8):38-42.
[3]王毅.铝合金车轮在汽车上的应用效果[J].客车技术与研究,2002,5(24):37-38
[4]蒋鹏.铸造锻造技术在铝合金轮毂成形中的应用[J].汽车工艺与材料,1999(5):1-3
[5]于铭.铝制车轮[J].当代汽车,1991(3):39-42
[6]柳百成,荆涛.铸造工程的模拟仿真与质量控制[M].北京:机械工业出版社,2001.
[7]周业明,李莉,胡志男等.铸造有限元模拟预测铸钢件的宏观缩孔缺陷[J].铸造,2001.
[8]赖华清.压铸工艺及模具[M].北京:机械工业出版社,2004
[9]潘宪曾.压铸模设计手册(第2版)[M].北京:机械工业出版社,1999
[10]张希俊,张方,张红松.铸造过程计算机数值模拟的国内外研究概况[J].昆明理工大学学报,2003(2):55-58
[11]林毅.压铸模CAE分析及并行设计技术的工程应用[J].模具制造,2002(6):10-12
[12]柳百成,康进武.铸件凝固过程的宏观及微观计算机模拟研究[J].铸造工程.造型材料,2000,24(3):1-6
[13]Shoumei XIONG,Baicheng LIU,Liangrong JIA.Study on Numerical Simulation of Mold Filling and Solidfiieation Proeesses under Perssure Conditio[J].J.Mater.Sci.Technol.2002(5):413-416
[14]帕坦卡S V.传热与流体流动的数值计算[M].科学出版社,1984
[15]李嘉荣,钟振纲.计算机技术在铸造中的应用现状与发展趋势[J].材料工程,1996(11):3-8
[16]Bastain K.M..A Look Back at the 20th Century Casting Process Simulation[J].Moden Casting,2000(12):43-45
[17]Hirt C.W.,Nichols B.D..Volume of Fluid Method for the Dynamics of Free Boundaries[J].Comp Phys,1981,39:201-225
[18]AL Rawahji N.Numerical Simulation of Dendritiesolidification with Convection:Three dimensional Flow[J].Journal of Computational Physies,2004,194:677-696
[19]陈梅清.铸件凝固过程数值模拟[M].重庆.重庆大学出版社.1991
[20]大中逸雄.计算机传热凝固解析入门[M].北京.机械工业出版社.1998
[21]张世辉.铸件凝固过程数值模拟软件在生产中的应用[J].铸造,1999.5
[22]蒋玉明.件凝固模拟和铸造工艺CAD的发展[J].都科技大学学报.1994.1-2
[23]柳百成.铸件充型凝固过程数值模拟国内外研究进展[J].铸造,1998(8):40-43
[24]林国荣.铸件形成过程计算机数值模拟的发展及应用[J].现代铸铁,2001(2):8-9
[25]李梅娥,邢建东.铸造应力场数值模拟的研究进展[J].铸造,2002,51(3):141-143
[26]张世辉,周佩超,吴振超.铸件凝固过程计算机数值模拟软件在生产中的应用[J].铸造,1999(5):18-20
[27]Si H.M..A Hybrid Method forCasing Proeess Simulation by combining FDM and FEM with an Effieient Data Conversion Algorithm[J].Materials Proeessing Teehnology,2003,133:311-321
[28]Zhang H,Wang X Y,Zheng L L.Numerical Simulation of Nueleation,Solidifieation and Mierostrueture Formation in Thermal Spraying[J].International Journal of Heat and Mass Transfer,2004,47:2191-2203
[29]许庆彦,柳百成.铸造合金凝固组织的计算机模拟与预测[J].稀有金属材料与工程,2003,32(6):401-405.
[30]Midea T.Process Simulation Software Round-up[J].ModernCasing,2002,90(8):40-45
[31]周丹晨,蒋玉明,杨屹.国外铸件充型凝固过程数值模拟软件介绍[J].热加工工艺,2000(5):45-46
[32]王金华.铸件结构设计[M].北京.机械工业出版社,1983.7-24
[33]王喜军.铸件充型与凝固过程数值模拟集成软件系统的研究[D].哈尔滨工业大学工学硕士学位论文,1998.05
[34]李世宁.大型薄壁铸件充型过程数值模拟.哈尔滨工业大学硕士学位论文,2002.05
[35]Barkhudarov M.Simulation of surface Turbulence Fluid Phenomena.During Mold Filling AFS Transactions.1995.
[36]麻向军,阳晓军.垂直缝隙式浇注系统充型特性的数值模拟[J].机械研究与应用,2004(4):33-34
[37]美国通力(UFC)有限公司.ProCAST培训简要教程
[38]杨亚杰.铸造模拟软件ProCAST[J].CAD/CAM与制造业信息化,2004,Zl
[39]刑涛 凝固过程数值模拟[M].北京.电子工业出版社2003
[40]胡红军.ProCAST软件的特点及其在铸件成形过程中的应用[J].热加工工艺,2005,(1):70-71.
[41]Electronic Data System Corporation,Unigraphics Division.UG/CAD User Guide.2001
[42]林清安编著.Pro/ENGINEER20001模具设计,北京大学出版社
[43]黄圣杰,张盖三,洪立群编著.Pro/ENGINEER2001高级开发实例.北京:电子工业出版社,2002.2
[44]ESI.ProCAST User Manual[M].2007
[45]于百库等.Pro/E与ProCAST接口方式的探讨[J].中国铸造装备与技术.2002,1
[46]杨亚杰.铸造模拟软件ProCAST[J].CAD/CAM与制造业信息化,2004年21期
[46]杨亚杰.铸造模拟软件ProCAST[J].CAD/CAM与制造业信息化,2004年21期
[47]吴春苗.压铸实用技术.广州:广东科技出版社,2003
[48]压铸模具设计手册编写组.压铸模设计手册.北京:机械工业出版社,1981,
[49]潘复生,张丁飞等.铝合金及应用.北京:化学工业出版社,2006.57-97.