摘要
针对某新能源汽车前壳体压铸件,应用数值模拟方法,通过对比不同浇注系统下铝液流动充型凝固状态,预测铸件可能产生气孔、缩孔、冷隔等缺陷的位置,从设计上进行针对性的优化改善。模拟结果表明,浇注系统设计不合理导致填充不平衡、末端冷料包卷等问题。通过对浇注系统迭代优化,实现了平稳有序的填充,显著降低了飞轮腔末端及水道部位的气孔与冷隔风险。基于模拟设计的挤压销、活块及冷却系统有效控制了厚壁部位缩孔。试制验证显示,铸件内部质量良好,关键密封面与轴承孔加工后无气孔外露,泄漏测试符合严苛标准,证实了该工艺方案的可靠性。
This paper focuses on the die-casting process of a front housing for a new energy vehicle,employing numerical simulation methods to compare the filling and solidification states of molten aluminum under different gating systems.It predicts potential defect locations such as gas pores,shrinkage cavities,and cold shuts,and proposes targeted design optimizations.The simulation results show that the initial scheme has problems such as unbalanced filling and cold material entrainment at the end.The final casting scheme obtained through iterative optimization achieves smooth and orderly filling,significantly reducing the risks of porosity and cold shuts at the end of the flywheel cavity and the water channel area.The extrusion pins,loose pieces and cooling system designed based on simulation effectively control the shrinkage cavities in the thick-walled parts.The trial production verification shows that the internal quality of the casting is good,no porosity is exposed after the processing of key sealing surfaces and bearing holes,and the leakage test meets strict standards,which confirms the reliability of the process scheme.
作者
肖厚涛
廖建强
管维健
刘华
安肇勇
XIAO Hou-tao;LIAO Jian-qiang;GUAN Wei-jian;LIU Hua;AN Zhao-yong(Guangdong Hongtu Wuhan Die-casting Co.,Ltd.,Wuhan Hubei,430208,China;Guangdong Hongtu Technology(holdings)Co.,Ltd.,Zhaoqing Guangdong,526105,China)
出处
《铸造设备与工艺》
2025年第6期18-27,共10页
Foundry Equipment & Technology
关键词
前壳体
数值模拟
浇注系统
压铸工艺
front housing
numerical simulation
pouring system
die casting process
