To eliminate the shrinkage porosity in low pressure casting of an A356 aluminum alloy intake manifold casting, numerical simulation on fi lling and solidifi cation processes of the casting was carried out using the Pr...To eliminate the shrinkage porosity in low pressure casting of an A356 aluminum alloy intake manifold casting, numerical simulation on fi lling and solidifi cation processes of the casting was carried out using the ProCAST software. The gating system of the casting is optimized according to the simulation results. Results show that when the gating system consists of only one sprue, the fi lling of the molten metal is not stable; and the casting does not follow the sequence solidifi cation, and many shrinkage porosities are observed through the casting. After the gating system is improved by adding one runner and two in-gates, the fi lling time is prolonged from 4.0 s to 4.5 s, the fi lling of molten metal becomes stable, but this casting does not follow the sequence solidifi cation either. Some shrinkage porosity is also observed in the hot spots of the casting. When the gating system was further improved by adding risers and chill to the hot spots of the casting, the shrinkage porosity defects were eliminated completely. Finally, by using the optimized gating system the A356 aluminum alloy intake manifold casting with integrated shape and smooth surface as well as dense microstructure was successfully produced.展开更多
The intake system of a racing engine plays a crucial role in determining its performance,particularly in terms of volumetric efficiency,power output,and throttle response.According to Formula Society of Automotive Eng...The intake system of a racing engine plays a crucial role in determining its performance,particularly in terms of volumetric efficiency,power output,and throttle response.According to Formula Society of Automotive Engineers(FSAE)regulations,the engine intake systemmust incorporate a 20mmdiameter flow-limiting valve within the intake manifold.This restriction significantly reduces the airflow into the engine,leading to a substantial drop in power output.To mitigate this limitation,the intake system requires a redesign.In this study,theoretical calculations and one-dimensional thermodynamic simulations are employed to determine the optimal parameters for the intake system.A numerical simulation of the intake system’s flow field is then conducted to refine its structure and layout.Finally,experiments are performed on an engine equipped with the optimized intake system,and its feasibility is evaluated based on experimental results.Thefindings indicate that the maximumengine torque increases from56.36 to 59.91 N⋅m,while the maximum power output rises from 59.16 to 63.94 kW.To further enhance performance and adaptability across different competitions,a variable-length intakemanifold control system is also designed,improving both power delivery and overall operational stability of the racing car.展开更多
基金supported by the National Natural Science Foundation of China(No.51204124)the China Postdoctoral Science Foundation(No.2012M511610)the Scientific Research Foundation of Wuhan Institute of Technology(No.14125041)
文摘To eliminate the shrinkage porosity in low pressure casting of an A356 aluminum alloy intake manifold casting, numerical simulation on fi lling and solidifi cation processes of the casting was carried out using the ProCAST software. The gating system of the casting is optimized according to the simulation results. Results show that when the gating system consists of only one sprue, the fi lling of the molten metal is not stable; and the casting does not follow the sequence solidifi cation, and many shrinkage porosities are observed through the casting. After the gating system is improved by adding one runner and two in-gates, the fi lling time is prolonged from 4.0 s to 4.5 s, the fi lling of molten metal becomes stable, but this casting does not follow the sequence solidifi cation either. Some shrinkage porosity is also observed in the hot spots of the casting. When the gating system was further improved by adding risers and chill to the hot spots of the casting, the shrinkage porosity defects were eliminated completely. Finally, by using the optimized gating system the A356 aluminum alloy intake manifold casting with integrated shape and smooth surface as well as dense microstructure was successfully produced.
基金supported by the Key Laboratory of Automotive Power Train and Electronics(Hubei University of Automotive Technology)(ZDK1201505)Auto Parts TechnologyHubei Province Collaborative Innovation Project(2015XTZX04).
文摘The intake system of a racing engine plays a crucial role in determining its performance,particularly in terms of volumetric efficiency,power output,and throttle response.According to Formula Society of Automotive Engineers(FSAE)regulations,the engine intake systemmust incorporate a 20mmdiameter flow-limiting valve within the intake manifold.This restriction significantly reduces the airflow into the engine,leading to a substantial drop in power output.To mitigate this limitation,the intake system requires a redesign.In this study,theoretical calculations and one-dimensional thermodynamic simulations are employed to determine the optimal parameters for the intake system.A numerical simulation of the intake system’s flow field is then conducted to refine its structure and layout.Finally,experiments are performed on an engine equipped with the optimized intake system,and its feasibility is evaluated based on experimental results.Thefindings indicate that the maximumengine torque increases from56.36 to 59.91 N⋅m,while the maximum power output rises from 59.16 to 63.94 kW.To further enhance performance and adaptability across different competitions,a variable-length intakemanifold control system is also designed,improving both power delivery and overall operational stability of the racing car.
