半固态压铸模设计研究及压铸过程数值模拟
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摘要
半固态金属成形技术具有成形件组织致密、表面平整光滑、力学性能高、模具寿命长等优点,该技术已经逐步在发达国家得到了商业应用,但无论在理论上还是技术上,该技术都需要进一步完善。而对于半固态压铸来讲,特别是在模具设计和工艺方面研究的还很少,到目前为止,还没有一个量化标准。
本文针对铝合金半固态浆料的粘度及压铸充型特点,进行了半固态流变成形标准试样的压铸模具设计,模具设计了自动控制加热系统和不同的内浇口的截面积,为研究半固态压铸模具设计及压铸工艺提供了技术保证。
利用铸造模拟软件ProCAST对半固态压铸件的充型及凝固过程进行数值模拟,通过正交试验的方法,获得了最优的压铸工艺参数:即压射速度为1m/s,浇注温度为580℃,模具预热温度为300℃。半固态浆料在整个充填过程中非常平稳,基本没有飞溅,直至充满铸件。
通过电磁搅拌的方法制备出半固态压铸实验的所需铝合金浆料,其浆料的组织圆整,且分布均匀。其搅拌工艺参数为搅拌温度为580℃,搅拌电流为450A,搅拌频率为6Hz,搅拌时间为25min。
通过半固态压铸实验,验证了数值模拟结果的正确性,并且证明了在压铸模无加热时,铸件难以充满型腔且缺陷较多,而在压铸模加热时,铸件成形良好,表面光滑。压射速度在0.5～4m/s范围内,随着压射速度的提高,半固态压铸件的力学性能先增大后减小。而对于压铸模内浇口截面积来讲,在铸件壁厚的范围内,内浇口截面积尺寸越大就越有利于成型,铸件质量就越好。
Semi-solid metal forming has an extensive applications in many industries, due to its many significant advantages, for instance, the formed part possesses compacter microstructure,higher mechanical property, longer die life, etc. Semi-solid metal forming technology has been gradually commercial applications in developed countries. But both in theory and technology, the technology requires further refinement. For semi-solid die casting is concerned, especially in the semi-solid die casting mold design and die casting process, so far , there is few studies and no quantitative criteria.
With consideration of the viscosity of semi-solid aluminum alloy slurry and the mold filling characteristics in die casting, the die-casting mould for semi-solid aluminum alloy has been designed and manufactured. In order to study the impact of mold heating system and the cross-sectional area of ingate on the process of mold filling and mechanical properties, the mold was designed automatic control of heating systems and different cross-sectional area of ingate, so it achieves semi-solid aluminum alloy die-casting forming, and provides a theoretical basis on structure and properties.
The process of mold filling and solidification of semi-solid aluminum alloy in die casting was simulated by using ProCAST software. Through orthogonal test method, we obtained the optimal process:injection speed was 1m/s, casting temperature was 580℃, mould temperature was 300℃. The simulation results indicated that the semi-solid metal flows smoothly in the mould cavity. Molten metal splash has not been observed.
The semi-solid slurry prepared by magnetic stirring meet the test of die-casting, and its organizations was round and small. The semi-solid slurry were obtained as follows: stirring temperature was 580℃, stirring electric current of 450A, stirring frequency of 6Hz, stirring time was 25min.
Through the semi-solid die casting experiments, the results indicate that the correctness of the numerical simulation results.Without heating of mould, the production of semi-solid die casting is not full, and there are many defects in casting. When mould is heated, the production of the die casting has complete shape, and smooth surface. When the injection speed in the 0.5~4m/s range, With the increase of injection speed, the mechanical properties of semi-solid die casting first increases and then decreased. Within the range of cross-section of castings, the larger size of ingate has important effect on increase of the quality of die casting.
本文针对铝合金半固态浆料的粘度及压铸充型特点,进行了半固态流变成形标准试样的压铸模具设计,模具设计了自动控制加热系统和不同的内浇口的截面积,为研究半固态压铸模具设计及压铸工艺提供了技术保证。
利用铸造模拟软件ProCAST对半固态压铸件的充型及凝固过程进行数值模拟,通过正交试验的方法,获得了最优的压铸工艺参数:即压射速度为1m/s,浇注温度为580℃,模具预热温度为300℃。半固态浆料在整个充填过程中非常平稳,基本没有飞溅,直至充满铸件。
通过电磁搅拌的方法制备出半固态压铸实验的所需铝合金浆料,其浆料的组织圆整,且分布均匀。其搅拌工艺参数为搅拌温度为580℃,搅拌电流为450A,搅拌频率为6Hz,搅拌时间为25min。
通过半固态压铸实验,验证了数值模拟结果的正确性,并且证明了在压铸模无加热时,铸件难以充满型腔且缺陷较多,而在压铸模加热时,铸件成形良好,表面光滑。压射速度在0.5～4m/s范围内,随着压射速度的提高,半固态压铸件的力学性能先增大后减小。而对于压铸模内浇口截面积来讲,在铸件壁厚的范围内,内浇口截面积尺寸越大就越有利于成型,铸件质量就越好。
Semi-solid metal forming has an extensive applications in many industries, due to its many significant advantages, for instance, the formed part possesses compacter microstructure,higher mechanical property, longer die life, etc. Semi-solid metal forming technology has been gradually commercial applications in developed countries. But both in theory and technology, the technology requires further refinement. For semi-solid die casting is concerned, especially in the semi-solid die casting mold design and die casting process, so far , there is few studies and no quantitative criteria.
With consideration of the viscosity of semi-solid aluminum alloy slurry and the mold filling characteristics in die casting, the die-casting mould for semi-solid aluminum alloy has been designed and manufactured. In order to study the impact of mold heating system and the cross-sectional area of ingate on the process of mold filling and mechanical properties, the mold was designed automatic control of heating systems and different cross-sectional area of ingate, so it achieves semi-solid aluminum alloy die-casting forming, and provides a theoretical basis on structure and properties.
The process of mold filling and solidification of semi-solid aluminum alloy in die casting was simulated by using ProCAST software. Through orthogonal test method, we obtained the optimal process:injection speed was 1m/s, casting temperature was 580℃, mould temperature was 300℃. The simulation results indicated that the semi-solid metal flows smoothly in the mould cavity. Molten metal splash has not been observed.
The semi-solid slurry prepared by magnetic stirring meet the test of die-casting, and its organizations was round and small. The semi-solid slurry were obtained as follows: stirring temperature was 580℃, stirring electric current of 450A, stirring frequency of 6Hz, stirring time was 25min.
Through the semi-solid die casting experiments, the results indicate that the correctness of the numerical simulation results.Without heating of mould, the production of semi-solid die casting is not full, and there are many defects in casting. When mould is heated, the production of the die casting has complete shape, and smooth surface. When the injection speed in the 0.5~4m/s range, With the increase of injection speed, the mechanical properties of semi-solid die casting first increases and then decreased. Within the range of cross-section of castings, the larger size of ingate has important effect on increase of the quality of die casting.
引文
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[3]吴秀铭.21世纪最有发展前景的现代加工新技术—半固态加工.中国有色金属加工,2000,6:17-21
[4]管仁国,马伟民.金属半固态成形理论与技术[M].北京:冶金工业出版社,2005
[5]毛卫民.半固态金属成型技术[M].北京:机械工业出版社,2004
[6]罗守靖.半固态金属成形讲义.哈尔滨工业大学教材科,2003.13-15
[7]杨湘杰.半固态合金触变成形流变特性及其浇道系统的研究.上海大学博士论文.1999.69-120
[8]史立峰.ZL201合金半固态触变压铸及数值模拟.东北大学硕士学位论文.2005.23-24
[9]张恒华.铝合金半固态触变成形技术及其仿真研究.上海大学博士学位论文.2003.36-38
[10] H.V.Atkinson*.Modelling the semisolid Processing of metallic alloys.Progress in Materials Science ,2005(50):341-412
[11] QuaakCJ,KatgermanL,KoolWH.In:KirKwoodDH,KaPranos,Peditors.Proc.4th Int.Conf.Semi Solid Processing of Alloys and Composites.University of Sheffield.1996.35-39
[12] Midson S P.The commercial status of semi-solid casting in the USA,In:Kirkwood D H and Kapranos P.Proc of the 4th Int .Conf.on Semi-solid Processing of Alloys and Composites,University of Sheffield,England,June 19-21,1996.UK:Department of Engineering Materials,University of Sheffield,1996.251-255
[13]黄勇.高熔点合金半固态压铸模研究.模具工业,2003,4:44-47
[14] Shuming XING,Jianbo TAN,Lizhong ZHANG.Study on key problems on industrializations of semi-solid rheologic forming processes.Proceedings of the 8th international S2P conference. Limassol Cyprus.21-23,Sep,2004.11
[15]潘宪曾.正确选择慢压铸速度.铸造技术,2005,26(5):397-400
[16]吴树森,李东南,毛有武等.半固态流变压铸AZ91D镁合金的组织与性能.铸造,2002,51(10):583-586
[17]肖泽辉,罗吉荣,吴树森等.AZ91D半固态流变压铸成形的研究.工艺技术,2004,2:41-42
[18] Spencer D B,Flemings M C.Rheocasting.Mater.Sci.Eng.1976,25:103-107.
[19] Fan Z,Ji S,Bevis M J.Twin-screw rheomoulding-A new semi-solid processing technology.Proc.Of 6th Int.conference,Semi-solid Procesing of Alloy sand Composites.Editors:G.L.Chiarmetta-M,Rosso,Turin,Italy,Sept.27-29,2000.61-66
[20] Hitrt G,Cremer R,Winkelmann A.Mater J.Process,Technol.,1994,45:359
[21]崔成林,毛卫民,李述刚等.非枝晶AlSi7Mg合金半固态触变成形研究.材料科学与工艺,2001,9(2):122-125
[22]张奎,刘国钧,张景新等.铝合金半固态加工技术应用.中国有色金属学报,2000,36(增刊1):135-140
[23]王平,刘勇,路贵民等.半固态Y112铝合金成形组织与性能.轻合金加工术,2004,32(10):4-5
[24]冯鹏发,唐靖林,李双寿等.半固态合金流变成形技术的研究现状与发展.铸造,2004,53(12):963-967
[25]刘艳华,曾东保,冯赟. A380铝合金液态与半固态压铸件热处理前后组织性能研究.金属铸锻焊技术,2008.50-52
[26] Asquith B M,The use of process monitoring to minimize scrap in the die casting process.(Proc.)the 19th International die casting congress and exposition,Minneapolis,Minnesota,UAS,Nov2-6,1997,T97-063
[27] The Engineering Staff of Alumax Engineered Metal Processes Inc. Semi-solid forging at Alumax.Light Metal Age,1994,52(9-10):32-34
[28] Nichols B D.Hirt C W and Hotchkiss R S.SOLA-VOF: A solution algorithm fortransient fluid with multiple free boundaries.Los Alamos Scientific Report.LA-8355,1980
[29] Nishida Y .Droste W and Engler S.The air-gap formation Process at the casting-mold interface and the heat transfer mechanism through the gap.Metal Trans.2001.58-60
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