Casting method of large-size asymmetric thin-wall aluminum alloy
By setting runners and cold iron in large-size asymmetric thin-wall aluminum alloy castings, and adjusting process parameters through simulation simulation, the problem of difficult castings in the existing technology is solved, and high-quality and efficient casting production is achieved , shortened R&D cycle and reduced costs.
Patent Information
- Application Number
- CN202411218203.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-09-02
- Publication Date
- 2024-12-10
AI Technical Summary
The prior art is difficult to cast large-size asymmetric thin-wall aluminum alloy castings with high quality and high efficiency, and the process is complex and the trial and error cost is high, making it difficult to meet the requirements of high precision and high performance.
By pre-setting runners and cold iron, and using simulation simulation to adjust the quantity and holding time of cold iron, the process of castings is optimized, including surface mesh and body mesh division, simulation simulation and multiple adjustments, and finally high-quality Casting production.
Through simulation and optimization process, the R&D cycle is shortened, the quality and performance of castings are improved, and the requirements of tensile strength, hardness and elongation are met, and the human and material costs are reduced.
Smart Images
Figure CN119098569A_ABST
Abstract
Description
Technical Field
[0001] The invention relates to the field of aluminum alloy casting, and in particular to a large-size asymmetric thin-walled aluminum alloy casting method. Background Art
[0002] The casting technology requirements for a large-sized asymmetric thin-walled aluminum alloy casting are that the appearance should not have any dents or protrusions, the flaw detection level of the casting should not exceed level 2, the tensile strength should be ≥275MPa, the hardness should be ≥80HB, and the elongation should be ≥2%. Due to its large size and complex structure, the difficulty of the casting process has increased significantly, and the trial and error cost is relatively high. At the same time, the manufacturing process of this casting is relatively complex, the requirements for product performance and precision are relatively high, and the product cycle is relatively long, which poses new challenges to ensuring product reliability.
[0003] There is no effective solution to the problem that it is difficult to cast the casting with high quality and high efficiency in the prior art. Summary of the invention
[0004] To solve the above problems, the present invention provides a large-size asymmetric thin-walled aluminum alloy casting method, which improves the quality of the casting during final production by pre-setting the runner and chiller, and further increasing the number of chillers and adjusting the holding time through simulation results.
[0005] To achieve the above-mentioned purpose, the present invention provides a large-size asymmetric thin-walled aluminum alloy casting method, comprising: determining the number of runners according to the size requirements of the target workpiece, and setting chillers at the inner cavity hot spot and the outer wall; performing surface meshing and volume meshing on the model, determining the casting material and boundary conditions, and then performing simulation to obtain a first simulation result; adjusting the holding time, the number and position of chillers according to the first simulation result to obtain an adjusted model; performing simulation on the adjusted model again to obtain a second simulation result; and producing according to the second simulation result to obtain the target workpiece.
[0006] Further optionally, the number of the runners is 8, and the 8 runners are evenly arranged.
[0007] Further optionally, 372858 surface grids and 9420138 volume grids are divided.
[0008] Further optionally, the boundary conditions include: a casting temperature of 710° C., the sand mold and the chill are at room temperature, low-pressure casting is adopted, the heat transfer coefficient between the chill and the casting is 3000, and the heat transfer coefficient between the chill and the sand mold is 2000.
[0009] Further optionally, producing according to the second simulation result to obtain a target workpiece includes: producing according to the second simulation result to obtain a workpiece to be inspected; performing a flaw detection test on the workpiece to be inspected, and obtaining a qualified target workpiece if the workpiece passes the flaw detection test.
[0010] The above technical solution has the following beneficial effects: by designing the casting with preset conditions and performing simulation on this basis, the parts of the casting that need to be adjusted are obtained, and the corresponding conditions are adjusted according to the situation of the parts that need to be adjusted, thereby optimizing the casting process, thereby greatly shortening the product development cycle and saving manpower and material resources. BRIEF DESCRIPTION OF THE DRAWINGS
[0011] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.
[0012] Figure 1 It is a flow chart of a large-size asymmetric thin-walled aluminum alloy casting method provided by an embodiment of the present invention. DETAILED DESCRIPTION
[0013] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.
[0014] In order to solve the problem that castings are difficult to cast with high quality and high efficiency in the prior art, an embodiment of the present invention provides a large-size asymmetric thin-walled aluminum alloy casting method. Figure 1 Flow chart of a large-size asymmetric thin-walled aluminum alloy casting method provided by an embodiment of the present invention. Figure 1 As shown, the method includes:
[0015] S1. Determine the number of runners according to the size requirements of the target workpiece, and set chillers at the inner cavity hot spot and outer wall;
[0016] The casting adopts the gap casting scheme, designs the initial number of runners, and sets chillers in the inner cavity hot spot and outer wall. The casting method adopts low-pressure casting to ensure the smooth flow of metal liquid, prevent the generation of air entrapment, and reduce the possibility of air holes.
[0017] S2, performing surface meshing and volume meshing on the model, determining the casting material and boundary conditions, and then performing simulation to obtain a first simulation result;
[0018] The model is meshed, and volume and surface meshes are divided according to the size of the target workpiece. Simulation is performed under the initial boundary conditions, and the simulation results are analyzed, mainly including the analysis of the simulation results of the temperature field during the filling and solidification process and the prediction analysis of casting defects.
[0019] Furthermore, the simulation process can be simulated and analyzed through ProCAST.
[0020] S3, adjusting the holding time, the number and position of the chills according to the first simulation result to obtain an adjusted model;
[0021] After analyzing the simulation results, it was found that there were many loose defects inside the casting. Based on the simulation results, the process was optimized. On the one hand, the process design was optimized, that is, cold iron was added to the thick and large parts inside the casting to ensure that the thick and large parts solidified first during the casting process; on the other hand, the process parameters were optimized, mainly including increasing the holding time, so as to ensure the density of the casting on the basis of complete filling of the casting.
[0022] S4, simulating the adjusted model again to obtain a second simulation result;
[0023] The model after process adjustment is simulated for the second time to obtain the second simulation result. The second simulation result also needs to analyze the filling and solidification process and defects.
[0024] S5. Produce according to the second simulation result to obtain a target workpiece.
[0025] The model can be further optimized based on the analysis results, and then the actual production is carried out according to the optimized plan to obtain the target workpiece. The quality of the target workpiece is greatly improved and meets all the requirements of the workpiece.
[0026] As an optional implementation, the number of runners is 8, and the 8 runners are evenly arranged.
[0027] As an optional implementation, 372,858 surface grids and 9,420,138 volume grids are divided.
[0028] As an optional implementation, the boundary conditions include: the casting temperature is 710°C, the sand mold and the chill are at room temperature, low pressure casting is adopted, the heat transfer coefficient between the chill and the casting is 3000, and the heat transfer coefficient between the chill and the sand mold is 2000.
[0029] As an optional implementation, producing according to the second simulation result to obtain a target workpiece includes:
[0030] S501, producing according to the second simulation result to obtain a workpiece to be inspected;
[0031] S502, performing a flaw detection test on the workpiece to be inspected, and if the flaw detection test passes, a qualified target workpiece is obtained.
[0032] The actual workpieces to be tested are tested for performance. If the flaw detection grade of the casting is measured to be level 2, it means that the target workpiece has passed the flaw detection test and is qualified. The target workpiece has good density, uniform grain distribution, and mechanical properties that meet the requirements.
[0033] The above technical solution has the following beneficial effects: by designing the casting with preset conditions and performing simulation on this basis, the parts of the casting that need to be adjusted are obtained, and the corresponding conditions are adjusted according to the situation of the parts that need to be adjusted, thereby optimizing the casting process, thereby greatly shortening the product development cycle and saving manpower and material resources.
[0034] The specific implementation methods of the above invention further illustrate the objectives, technical solutions and beneficial effects of the present invention in detail. It should be understood that the above content is only the specific implementation methods of the present invention and is not intended to limit the protection scope of the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the protection scope of the present invention.
Claims
1. A large-size asymmetric thin-walled aluminum alloy casting method, characterized in that: include: Determine the number of runners according to the size requirements of the target workpiece, and set chillers at the inner cavity hot spot and outer wall; Performing surface meshing and volume meshing on the model, and performing simulation after determining the casting material and boundary conditions to obtain a first simulation result; According to the first simulation result, the holding time, the number and position of the chills are adjusted to obtain an adjusted model; Performing simulation again on the adjusted model to obtain a second simulation result; Production is performed according to the second simulation result to obtain a target workpiece.
2. The large-size asymmetric thin-walled aluminum alloy casting method according to claim 1 is characterized in that: The number of runners is 8, and the 8 runners are evenly arranged.
3. The large-size asymmetric thin-walled aluminum alloy casting method according to claim 1, characterized in that: There are 372858 surface meshes and 9420138 volume meshes.
4. The large-size asymmetric thin-walled aluminum alloy casting method according to claim 1, characterized in that: The boundary conditions include: The casting temperature is 710°C, the sand mold and chill are at room temperature, low-pressure casting is adopted, the heat transfer coefficient between the chill and the casting is 3000, and the heat transfer coefficient between the chill and the sand mold is 2000.
5. The large-size asymmetric thin-walled aluminum alloy casting method according to claim 1, characterized in that: Producing according to the second simulation result to obtain a target workpiece includes: Produce according to the second simulation result to obtain a workpiece to be inspected; A flaw detection test is performed on the workpiece to be inspected. If the workpiece passes the flaw detection test, a qualified target workpiece is obtained.