圆筒型镁合金铸件低压铸造工艺CAD
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摘要
由于低压铸造具有充型平稳、顺序凝固和压力补缩的特点，是生产圆筒形镁合金铸件的理想工艺之一。浇注系统的设计直接影响到铸件质量，生产大型铝镁合金铸件时常常应用缝隙式浇注系统。本课题研究了缝隙式浇注系统的参数设计规律，并以此结果建立了工艺参数设计数据库，开发了圆筒形镁合金铸件低压铸造工艺CAD系统。
本研究利用数值模拟技术和实际浇注实验研究了缝隙式浇注系统中缝隙宽度、缝隙长度、立筒直径、缝隙形式和冷铁设置等因素对圆筒形镁合金铸件充型和凝固过程的影响。以AutoCAD2004为平台，利用AutoCAD二次开发系统VBA建立圆筒形镁合金铸件低压铸造工艺CAD系统。通过DAO数据接口技术实现了在CAD系统中建立基于Access的关系型工艺参数数据库。本CAD系统采用参数化设计技术，使得系统可自动生成三维实体模型，提高了设计效率。
选择某镁合金舱体铸件为例，应用本CAD系统设计浇注系统，并对设计结果进行数值模拟验证和实际生产验证，结果表明本系统设计结果正确可行，可大幅度提高工艺设计效率，增加设计准确性。
Due to smooth mold filling, directional solidification and feeding under pressure, the low pressure casting process is one of well suitable methods to product the cylindric magnesium alloy casting. The design of the gate system is of particular importance in controlling the quality and performance of the castings. Usually, a slot gating system is used for the magnesium alloy casting in low pressure gating process. In this paper, the design methodology of the slot gate system is investigated, the database of the casting process is established, and a CAD system of the low pressure casting process is developed for the cylindric magnesium alloy casting.
Based on the numerical simulation and real casting experiment, the influence of the slot gate system on the filling and solidification process of the cylindric magnesium alloy casting is studied. With the VBA (Visual Basic for Application) technology, the CAD system is constructed on the secondary development platform of the AutoCAD2004. A parameter-interrelating Access database built in the CAD system is realized by using DAO (Data Access Object) data interface. The system utilizes the parameterized technology, a 3-dimensional solid model can be automatically generated by the system, and the design efficiency is obviously enhanced.
The CAD system been initially applied to the gating system design of some magnesium alloy castings from the missile industry, and the design results were analyzed and verified with numerical simulation and real casting production. The results show that the present CAD system is satisfactory, and the design efficiency and validity of the gating system design are improved.
本研究利用数值模拟技术和实际浇注实验研究了缝隙式浇注系统中缝隙宽度、缝隙长度、立筒直径、缝隙形式和冷铁设置等因素对圆筒形镁合金铸件充型和凝固过程的影响。以AutoCAD2004为平台，利用AutoCAD二次开发系统VBA建立圆筒形镁合金铸件低压铸造工艺CAD系统。通过DAO数据接口技术实现了在CAD系统中建立基于Access的关系型工艺参数数据库。本CAD系统采用参数化设计技术，使得系统可自动生成三维实体模型，提高了设计效率。
选择某镁合金舱体铸件为例，应用本CAD系统设计浇注系统，并对设计结果进行数值模拟验证和实际生产验证，结果表明本系统设计结果正确可行，可大幅度提高工艺设计效率，增加设计准确性。
Due to smooth mold filling, directional solidification and feeding under pressure, the low pressure casting process is one of well suitable methods to product the cylindric magnesium alloy casting. The design of the gate system is of particular importance in controlling the quality and performance of the castings. Usually, a slot gating system is used for the magnesium alloy casting in low pressure gating process. In this paper, the design methodology of the slot gate system is investigated, the database of the casting process is established, and a CAD system of the low pressure casting process is developed for the cylindric magnesium alloy casting.
Based on the numerical simulation and real casting experiment, the influence of the slot gate system on the filling and solidification process of the cylindric magnesium alloy casting is studied. With the VBA (Visual Basic for Application) technology, the CAD system is constructed on the secondary development platform of the AutoCAD2004. A parameter-interrelating Access database built in the CAD system is realized by using DAO (Data Access Object) data interface. The system utilizes the parameterized technology, a 3-dimensional solid model can be automatically generated by the system, and the design efficiency is obviously enhanced.
The CAD system been initially applied to the gating system design of some magnesium alloy castings from the missile industry, and the design results were analyzed and verified with numerical simulation and real casting production. The results show that the present CAD system is satisfactory, and the design efficiency and validity of the gating system design are improved.
引文
[1]Dwain M. M. A global review of magnesium parts in automobiles[J].Light Metal Age, 1996, (10):62
[2]Robert B. International magnesium association 54th annual world conference[J].Light Metal Age, 199?, (8): 72～75.
[3]Byton B C. Magnesium industry overview[J].Advanced Materials and Processes, 1996, (4): 9～16.
[4]Ruden T J, Albright D L. High Ductility Magnesium Alloys in Automotive Applications[J]. Advanced Mater and Processes, 1994,145(6): 28～32.
[5]A 凯也，A 斯待里特．压铸冶金学[M]．北京：机械工业出版社，1987，98．
[6]黄启德．镁合金市场趋势及工业应用前景[J]，金属工业，2000，(1)：74～77
[7]罗庚生，张志忠，吕有纲等．低压铸造[M]．北京：国防工业出版社，1989．
[8]金刚，叶英豪．CG125摩托车汽缸盖的低压铸造．铸造工程．2001，(4)：41～43
[9]姜国有，张向阳．薄壁耐压铝合金蜗壳的低压铸造[J]．铸造．1998，(3)：36～37
[10]唐多光，王海江，杨建中．低压铸造铝合金车圈若干技术问题的讨论[J]．特种铸造及有色合金．1997，(2)：49～52
[11]畅战朝，李昱．棘轮类铝铸件低压铸造工艺研究[J]．中国铸造装备与技术．2002，(2)：42～43
[12]吴浚郊．轿车发动机铝合金缸体和缸盖的铸造技术[J]．铸造技术．2002，(9)：273～275
[13]何素荣．砂型低压铸造大型铝铸件[J]．铸造技术．1996，(4)：20～23
[14]林明清．铸造及其经济性[M]．北京：机械工业出版社．1986．
[15]唐多光．21世纪低压铸造技术的展望[M]．特种铸造及有色合金．1998，(4)：28～31
[16]唐玉林，李维容，祝建勋．圣泉铸工手册[M]，沈阳：东北大学出版社，1999．
[17]董秀琦，王冬，叶荣茂．垂直缝隙式浇注系统的理论分析及模拟验证[M]．铸造．1993，(9)：1～8
[18]张启勋，王友序，吴孟怀，等．缝隙式浇注系统对铸件凝固过程的影响[J]．铸造技术．1991，(06)：44～47
[19]Flemings M C, Norton P J, Taylor H F. Performance of chills on high strength-high ductility sand-mold castings of various section thicknesses[J]. Transactions of American Foundrymens Society. 1958,66:336
[20]Flemings M C, Conrad H F, Taylor H F. A fluidity test for aluminum alloys; tripling fluidity with a new mold coating[J]. Transactions of American Foundrymen's Society. 1959,67:496
[21]Flemings M C, Poirer E J, Taylor H F. Premium quality magnesium castings
for missile applications[J]. Transactions of American Foundrymen s Society. 1960,68:497
[22]Flemings M C, Strachan R W, Poirier E J, Taylor H F. Performance of chills on high strength magnesium alloy sand casting of various section thicknesses[J]. Transactions of American Foundrymens Society. 1958,66:336
[23]Flemings M C, Strachan R W, Poirier E J, Taylor H F. Rigging design of high strength magnesium alloy castings [J]. Transactions of American Foundrymen's Society. 1958,66:241
[24]Flemings M C, Norton P J, Taylor H F. Rigging design of a typical high strength, high ductiIity aluminum casting[J]. Transactions of American Foundrymens Society. 1957,65:550
[25]Green R D. Porosity-free magnesium alloy castings thermal requirements [J]. Transactions of American Foundrymen s Society. 1960,68:245
[26]Ben-Ari E, Yaffe E, Bamberger M. Simulating filling and solidification of AZ91 magnesium alloy in gravity die casting [J]. Mat. Tech & Adv. Perf. Mat. 2001, 16:110-141
[27]Nelson K E. Premiumqua]ity magnesium sand castings [J]. Transactions of American Foundrymen's Society. 1961,69:756
[28]Saia A, Edelman R E, Gilmore H L. The gating and risering of counter-gravity poured magnesium-lithium castings [J]. Transactions of American Foundrymen's Society. 1967,75:199
[29j沈丙振，金平，王云爱，许庆彦，柳百成，李万鹏，乔劲松．铸造工艺CAD的开发及应用研究[J]．铸造技术．2001(4)，32
[30]王云爱，许庆彦，沈丙振，金平，柳百成。铸造工艺CAD中的工程数据库及其集成方法与途径[J]，热加工工艺，2002(2)，51
[31]兰宏志，吕志刚，姜不居，闫双景．跨平台熔模铸造工艺工装CAD[J]，特种铸造及有色合金，2001(1)，19
[32]刘烨，刘瑞祥．通用铸造工艺CAD的研究与开发[J]．中国铸造装备与技术．2001(4)，14
[33]王君卿，孙逊，苏仕方，等．铸造合金湍流和层流充型与凝固三维数值模拟软件及其在精密铸件上的应用[J]．铸造．2001(8)，450
[34]Richard D H. IT in Foundries Engineer Data Management and Layout Optimisation [J]. Foundryman. 1996, (2):7
[35]张士彦，闫平，姜华，等．铸钢件铸造工艺CAD软件的研制与应用[J]．铸造．2002(10)，628
[36]罗兰，董本行，黄天佑．基于UG的三维铸造工艺工装CAD系统[J]．铸造技术，2001(2)，8
[37]肖荣存，陈立亮，刘瑞祥．铸造冒口CAD设计模块的研究开发[J]．特种铸造及有色合金，2000(1)，42
[38]高秀兰，韩玉强，鲁开讲．铸件浇注系统CAD[J]．热加工工艺．2002(5)，68
[39]周丹晨，蒋玉明，杨屹．基于ANSYS的铸件浇冒口系统CAD的开发[J]．铸造．2001(4)，211
[40]高尚书，于志亚．三次方程解析法冒口计算[J]．铸造．2000(9)，533
[41]颜建军，林汉同，陈立亮，等．面向装配的回转体零件砂型低压铸造模具和工装的并行设计[J]．铸造．2002(8)，481
[42]H．M．卡尔金．轻金属铸件浇注系统[M]．北京：国防工业出版社，1982
[43]Carl Machover. Four Decads of Computer Graphics Computer Graphics and Application [M]. 1994
[44]赵汝嘉．CAD／CAM在机械工业中的应用[M]．西安交通大学出版社，1996．1
[45]赵汝嘉．CAD基础理论及应用[M]．西安交通大学出版社，1995．7
[46]黄少昌．计算机辅助机械设计技术基础[M]．北京：清华大学出版社，1998．2
[47]王钰．用VBA开发AutoCAD2000应用程序[M]．北京：人民邮电出版社，1999
[48]Computer Aided Design Report. Follow-up on Parametric Technology [M]. 1990
[49]铸造手册编委会．铸造手册[M]．北京：机械工业出版社，1994
[50]邬京利．低压铸造工艺参数的选择[J]．中国铸造装备与技术．2002(5)，28
[2]Robert B. International magnesium association 54th annual world conference[J].Light Metal Age, 199?, (8): 72～75.
[3]Byton B C. Magnesium industry overview[J].Advanced Materials and Processes, 1996, (4): 9～16.
[4]Ruden T J, Albright D L. High Ductility Magnesium Alloys in Automotive Applications[J]. Advanced Mater and Processes, 1994,145(6): 28～32.
[5]A 凯也，A 斯待里特．压铸冶金学[M]．北京：机械工业出版社，1987，98．
[6]黄启德．镁合金市场趋势及工业应用前景[J]，金属工业，2000，(1)：74～77
[7]罗庚生，张志忠，吕有纲等．低压铸造[M]．北京：国防工业出版社，1989．
[8]金刚，叶英豪．CG125摩托车汽缸盖的低压铸造．铸造工程．2001，(4)：41～43
[9]姜国有，张向阳．薄壁耐压铝合金蜗壳的低压铸造[J]．铸造．1998，(3)：36～37
[10]唐多光，王海江，杨建中．低压铸造铝合金车圈若干技术问题的讨论[J]．特种铸造及有色合金．1997，(2)：49～52
[11]畅战朝，李昱．棘轮类铝铸件低压铸造工艺研究[J]．中国铸造装备与技术．2002，(2)：42～43
[12]吴浚郊．轿车发动机铝合金缸体和缸盖的铸造技术[J]．铸造技术．2002，(9)：273～275
[13]何素荣．砂型低压铸造大型铝铸件[J]．铸造技术．1996，(4)：20～23
[14]林明清．铸造及其经济性[M]．北京：机械工业出版社．1986．
[15]唐多光．21世纪低压铸造技术的展望[M]．特种铸造及有色合金．1998，(4)：28～31
[16]唐玉林，李维容，祝建勋．圣泉铸工手册[M]，沈阳：东北大学出版社，1999．
[17]董秀琦，王冬，叶荣茂．垂直缝隙式浇注系统的理论分析及模拟验证[M]．铸造．1993，(9)：1～8
[18]张启勋，王友序，吴孟怀，等．缝隙式浇注系统对铸件凝固过程的影响[J]．铸造技术．1991，(06)：44～47
[19]Flemings M C, Norton P J, Taylor H F. Performance of chills on high strength-high ductility sand-mold castings of various section thicknesses[J]. Transactions of American Foundrymens Society. 1958,66:336
[20]Flemings M C, Conrad H F, Taylor H F. A fluidity test for aluminum alloys; tripling fluidity with a new mold coating[J]. Transactions of American Foundrymen's Society. 1959,67:496
[21]Flemings M C, Poirer E J, Taylor H F. Premium quality magnesium castings
for missile applications[J]. Transactions of American Foundrymen s Society. 1960,68:497
[22]Flemings M C, Strachan R W, Poirier E J, Taylor H F. Performance of chills on high strength magnesium alloy sand casting of various section thicknesses[J]. Transactions of American Foundrymens Society. 1958,66:336
[23]Flemings M C, Strachan R W, Poirier E J, Taylor H F. Rigging design of high strength magnesium alloy castings [J]. Transactions of American Foundrymen's Society. 1958,66:241
[24]Flemings M C, Norton P J, Taylor H F. Rigging design of a typical high strength, high ductiIity aluminum casting[J]. Transactions of American Foundrymens Society. 1957,65:550
[25]Green R D. Porosity-free magnesium alloy castings thermal requirements [J]. Transactions of American Foundrymen s Society. 1960,68:245
[26]Ben-Ari E, Yaffe E, Bamberger M. Simulating filling and solidification of AZ91 magnesium alloy in gravity die casting [J]. Mat. Tech & Adv. Perf. Mat. 2001, 16:110-141
[27]Nelson K E. Premiumqua]ity magnesium sand castings [J]. Transactions of American Foundrymen's Society. 1961,69:756
[28]Saia A, Edelman R E, Gilmore H L. The gating and risering of counter-gravity poured magnesium-lithium castings [J]. Transactions of American Foundrymen's Society. 1967,75:199
[29j沈丙振，金平，王云爱，许庆彦，柳百成，李万鹏，乔劲松．铸造工艺CAD的开发及应用研究[J]．铸造技术．2001(4)，32
[30]王云爱，许庆彦，沈丙振，金平，柳百成。铸造工艺CAD中的工程数据库及其集成方法与途径[J]，热加工工艺，2002(2)，51
[31]兰宏志，吕志刚，姜不居，闫双景．跨平台熔模铸造工艺工装CAD[J]，特种铸造及有色合金，2001(1)，19
[32]刘烨，刘瑞祥．通用铸造工艺CAD的研究与开发[J]．中国铸造装备与技术．2001(4)，14
[33]王君卿，孙逊，苏仕方，等．铸造合金湍流和层流充型与凝固三维数值模拟软件及其在精密铸件上的应用[J]．铸造．2001(8)，450
[34]Richard D H. IT in Foundries Engineer Data Management and Layout Optimisation [J]. Foundryman. 1996, (2):7
[35]张士彦，闫平，姜华，等．铸钢件铸造工艺CAD软件的研制与应用[J]．铸造．2002(10)，628
[36]罗兰，董本行，黄天佑．基于UG的三维铸造工艺工装CAD系统[J]．铸造技术，2001(2)，8
[37]肖荣存，陈立亮，刘瑞祥．铸造冒口CAD设计模块的研究开发[J]．特种铸造及有色合金，2000(1)，42
[38]高秀兰，韩玉强，鲁开讲．铸件浇注系统CAD[J]．热加工工艺．2002(5)，68
[39]周丹晨，蒋玉明，杨屹．基于ANSYS的铸件浇冒口系统CAD的开发[J]．铸造．2001(4)，211
[40]高尚书，于志亚．三次方程解析法冒口计算[J]．铸造．2000(9)，533
[41]颜建军，林汉同，陈立亮，等．面向装配的回转体零件砂型低压铸造模具和工装的并行设计[J]．铸造．2002(8)，481
[42]H．M．卡尔金．轻金属铸件浇注系统[M]．北京：国防工业出版社，1982
[43]Carl Machover. Four Decads of Computer Graphics Computer Graphics and Application [M]. 1994
[44]赵汝嘉．CAD／CAM在机械工业中的应用[M]．西安交通大学出版社，1996．1
[45]赵汝嘉．CAD基础理论及应用[M]．西安交通大学出版社，1995．7
[46]黄少昌．计算机辅助机械设计技术基础[M]．北京：清华大学出版社，1998．2
[47]王钰．用VBA开发AutoCAD2000应用程序[M]．北京：人民邮电出版社，1999
[48]Computer Aided Design Report. Follow-up on Parametric Technology [M]. 1990
[49]铸造手册编委会．铸造手册[M]．北京：机械工业出版社，1994
[50]邬京利．低压铸造工艺参数的选择[J]．中国铸造装备与技术．2002(5)，28