AZ91D镁合金摩托车轮毂铸锻复合成形研究
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摘要
在车辆轻量化进程加快的背景下,轻质合金的应用研究越来越受到各国的重视。近年来,交通工具上镁合金的用量逐年上升,但是大部分镁合金制件都是由压铸生产,难以满足结构件的性能要求。而镁合金的密排六方结构使得其塑性很差,难以对形状复杂的结构件进行锻造成形。针对既有高力学性能要求又有复杂形状要求的结构件成形需求,本研究提出了铸锻复合成形工艺方法。并且以典型零件摩托车轮毂为具体研究对象,对AZ91D镁合金摩托车轮毂的铸锻复合成形工艺进行研究。
本文依据压铸的三个最重要的参数建立三因素四水平16组正交实验方案,对轮毂进行三维实体建模,设计并优化浇注系统。模拟实验利用商业模流软件FLOW3D进行参数优化模拟,得出最佳参数组合L10,浇注温度690℃,压射速度4m/s,模具温度210℃。
实验分为压铸和铸锻复合成形两个部分,分别按照正交实验进行。实验发现压铸成形轮毂表面缺陷较多,如充不满、裂纹和冷隔;而铸锻复合成形轮毂表面缺陷很少,成形性优良。轮辐的拉伸实验表明,锻造力的存在使得轮辐的力学性能有极大的提高。铸锻复合成形轮辐的平均抗拉强度和延伸率相比压铸件分别提高了68.6%和108.9%,并且铸锻复合成形轮辐经可T6热处理后该比例进一步提高至88.7%和169.4%。
压铸件显微组织大都为粗大树枝晶,平均尺寸在180μm,其横断面的晶粒尺寸变化幅度很大,其间有枝晶偏析、氧化物夹杂、裂纹、气孔等缺陷。铸锻复合成形显微组织基本上为细小等轴晶,平均尺寸在25μm,晶粒尺寸变化范围很小,组织致密,裂纹、气孔被焊和,氧化物夹杂被细化弥散分布。
本次实验证明铸锻复合成形工艺是切实可行的,其生产率很高,制件力学性能优异,而且可经过后续热处理进一步提升力学性能。
Against this global development of vehicles’lightweighting, more attention was attached to the research and application of lightweight alloys. In recent years, the dosage of magnesium alloys for vehicles has been rising. So far as the vehicle dosage of magnesium alloys has been rising, the structural part are not well-matched, because of magnesium alloys’HCP structure and significant poor forgeability which lead to die-casting manufacture of magnesium alloy parts. Therefore, this paper suggested a forming process method of combination high productivity die-casting and high performance forging. As a typical motorcycle part, AZ91D magnesium alloy wheel has been produced to study this forming process.
Based on three most important die-casting parameters, this paper set up an experimental program of 16 orthogonal tests which belonged to three factors and four levels. By the building of three-dimensional solid modeling of motorcycle wheel, this paper designed and optimized gating system. After optimized and simulated with the commercial mold flow software FLOW3D, this paper obtained the optimal combination of parameters: pouring temperature of 690℃, injection speed 4m/s, mold temperature 210℃.
This experiment including two parts, common die-casting and combination of die-casting and forging, respectively, orthogonal test was done during each part. It was found that die-casting wheels had many surface defects, such as incomplete filling, cracks and cold shut; while wheels produced by the excellent formability method of combination die-casting and forging had less surface defects.
The tensile tests of spoke showed that the spoke’s mechanical properties have been greatly improved because of the existence of forging force. The average tensile and elongation of spokes increased by 68.6% and 108.9%, respectively, compared with die-casting spokes. What’s more, the performances were supposed to increase by 88.7% and 169.4% after the T6 heat treatment.
The microstructure of die-casting wheels was, mostly, consisted by dendrites with an average size of 180μm. Besides, the grain size had a large fluctuation from cross section view. The die-castings had many defects existed in die-casting wheel, such as dendritic segregation, oxide inclusions, cracks, holes and so on. By contrast, the microstructure of combination die-casting and forging wheels was, basically, composed of fine equiaxed grain with an average size of 25μm and a small fluctuation of grain size range from horizontal view. As the existence of forging force, defects and holes were welded. And oxide inclusions were refined and dispersed.
This study proved that this combination of die-casting and forging process was feasible. Mechanical properties of parts produced by this forming process with high productivity were excellent, and could be further enhanced by follow-up heat treatment.
本文依据压铸的三个最重要的参数建立三因素四水平16组正交实验方案,对轮毂进行三维实体建模,设计并优化浇注系统。模拟实验利用商业模流软件FLOW3D进行参数优化模拟,得出最佳参数组合L10,浇注温度690℃,压射速度4m/s,模具温度210℃。
实验分为压铸和铸锻复合成形两个部分,分别按照正交实验进行。实验发现压铸成形轮毂表面缺陷较多,如充不满、裂纹和冷隔;而铸锻复合成形轮毂表面缺陷很少,成形性优良。轮辐的拉伸实验表明,锻造力的存在使得轮辐的力学性能有极大的提高。铸锻复合成形轮辐的平均抗拉强度和延伸率相比压铸件分别提高了68.6%和108.9%,并且铸锻复合成形轮辐经可T6热处理后该比例进一步提高至88.7%和169.4%。
压铸件显微组织大都为粗大树枝晶,平均尺寸在180μm,其横断面的晶粒尺寸变化幅度很大,其间有枝晶偏析、氧化物夹杂、裂纹、气孔等缺陷。铸锻复合成形显微组织基本上为细小等轴晶,平均尺寸在25μm,晶粒尺寸变化范围很小,组织致密,裂纹、气孔被焊和,氧化物夹杂被细化弥散分布。
本次实验证明铸锻复合成形工艺是切实可行的,其生产率很高,制件力学性能优异,而且可经过后续热处理进一步提升力学性能。
Against this global development of vehicles’lightweighting, more attention was attached to the research and application of lightweight alloys. In recent years, the dosage of magnesium alloys for vehicles has been rising. So far as the vehicle dosage of magnesium alloys has been rising, the structural part are not well-matched, because of magnesium alloys’HCP structure and significant poor forgeability which lead to die-casting manufacture of magnesium alloy parts. Therefore, this paper suggested a forming process method of combination high productivity die-casting and high performance forging. As a typical motorcycle part, AZ91D magnesium alloy wheel has been produced to study this forming process.
Based on three most important die-casting parameters, this paper set up an experimental program of 16 orthogonal tests which belonged to three factors and four levels. By the building of three-dimensional solid modeling of motorcycle wheel, this paper designed and optimized gating system. After optimized and simulated with the commercial mold flow software FLOW3D, this paper obtained the optimal combination of parameters: pouring temperature of 690℃, injection speed 4m/s, mold temperature 210℃.
This experiment including two parts, common die-casting and combination of die-casting and forging, respectively, orthogonal test was done during each part. It was found that die-casting wheels had many surface defects, such as incomplete filling, cracks and cold shut; while wheels produced by the excellent formability method of combination die-casting and forging had less surface defects.
The tensile tests of spoke showed that the spoke’s mechanical properties have been greatly improved because of the existence of forging force. The average tensile and elongation of spokes increased by 68.6% and 108.9%, respectively, compared with die-casting spokes. What’s more, the performances were supposed to increase by 88.7% and 169.4% after the T6 heat treatment.
The microstructure of die-casting wheels was, mostly, consisted by dendrites with an average size of 180μm. Besides, the grain size had a large fluctuation from cross section view. The die-castings had many defects existed in die-casting wheel, such as dendritic segregation, oxide inclusions, cracks, holes and so on. By contrast, the microstructure of combination die-casting and forging wheels was, basically, composed of fine equiaxed grain with an average size of 25μm and a small fluctuation of grain size range from horizontal view. As the existence of forging force, defects and holes were welded. And oxide inclusions were refined and dispersed.
This study proved that this combination of die-casting and forging process was feasible. Mechanical properties of parts produced by this forming process with high productivity were excellent, and could be further enhanced by follow-up heat treatment.
引文
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[3]夏德宏,余涛.高速发展的绿色工程材料—金属镁[J].材料天地. 2004(6): 41-42.
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[5] E. Aghion, B. Bronfin, D. Eliezer. The role of the magnesium Industry in protecting the environment[J]. Journal of Materials Processing Technology. 2001(117): 381-385.
[6]文靖.半固态触变压铸AZ91D镁合金组织与性能的研究[D].兰州理工大学硕士学位论文: 2009:1-3.
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