压铸高精准度的铸造模流分析软件系统

FLOW-3D®

高精准度的铸造模流分析软件系统

---HighPressureDieCasting高压铸造简介

FLOW-ScienceChinaGravitycasting重力铸造PrecisionCasting熔模铸造LowPressureCasting低压铸造HighPressureDieCasting高压铸造TiltCasting倾斜铸造Lostfoamcasting消失模铸造SqueezeCasting挤压铸造CentrifugalCasting离心铸造ContinuousCasting连续铸造InvestmentCastingThixocastingSemi-solid半固态成型材料MaterialIron铸铁Steel铸钢Aluminum铝合金Magnesium镁合金Copper/Bronze

铜合金等可模拟的铸造方式铸件常见的缺陷问题缩孔：铸件在凝固过程中因为金属融汤的固化，在铸件上（表面或者是內部）产生局部凹陷或空孔合金融汤充填不良：模穴尚未完全填滿，但是融汤已经固化冷接纹：融汤前緣的温度过低，在金属相接时形成痕迹裂痕：因为热应力分布不均，使得铸件在局部区域发生裂痕气泡：铸件在成形过程中，因为融汤內卷气量过高，使得铸件局部区域內发生气泡集中的现象铸件缺陷会造成下列问题铸造属于大量量产方式，在量产过程中一旦发生问题，在短时间内可能会产生大量不良品铸件内的气孔聚集状况在铸件成形，进行热处理的时候，会因为气体膨胀而造成铸件表面鼓出而造成不良金属的冷却速度快，薄壁铸件或大型压铸件特别容易发生外观上的缺陷压铸模具虽然可以修改，但是不能无限期的进行修改。另外，模具修改需要额外的金钱及时间成本，会造成产品的开发成本上升镁合金压铸引擎进气岐管

产品规格:-材料：AZ91D;-尺寸精度要求非常高，

希望减少后续加工

-重量减轻，希望提升燃油效率

-公称厚度为

1.5-2.0mmAudiV84.2literengine.PhotoreproducedfromAdvancedMaterials&Processes,August2000.模具最佳化设计－步骤

I:流道与浇口设计进浇速度

~60m/sec,较薄区域速度达到

100m/sec减少喷流以及流动分离的状况减少空气与氧化膜混入的机会达到所有的流体可以通过所有浇口区域镁合金压铸引擎进气岐管由于金属导热速度快，而且产品不厚，充填速度相当快最佳化溢流井的分布减少喷流以及流动分离的状况减少空气与氧化膜混入的机会充填过程中的温度变化困在模穴表面的空气与氧化膜模具最佳化设计－步骤

II:充填模拟镁合金压铸引擎进气岐管可以设计冷却水路与加热机构可以模拟模具预热与冷却效果固化率分布开模后的模具温度分布模具最佳化设计－步骤III:固化模拟与冷却模拟镁合金压铸引擎进气岐管AudiV84.2literengine规格:重量

–7kg(15lb)产品公称厚度

–1.5mm(0.06in)1997年一月开始进行开发1997年十一月进行试量产AdvancedMaterials&Processes,August2000FLOW-3D®配合德国

KolbenschmidtPierburg开发完成

AudiV6engine1998优秀设计奖InternationalMagnesiumAssociation.

利用压铸制程开发完成，不需要多余的二次加工重量

-4.3kg(10lb)

–只有传统铝合金制品的一半公称厚度

–1.5mm(0.06in).目前产量每年

300,000件AdvancedMaterials&Processes,December1998FLOW-3D®配合德国

KolbenschmidtPierburg开发完成

戴姆克莱斯勒

S-classandCLcoupeIntakemanifoldfortheV12engines公称厚度

–1.5mm(0.06in).TwinignitionsystemAutomaticpartialcylindershutdownAnti-locksensor引擎规格：367hpand530Nmtorque.AdvancedMaterials&Processes,July2000FLOW-3D®配合德国

KolbenschmidtPierburg开发完成

高压铸造的卷气现象模拟FlowSeparation&BreakupDuringFilling

-空气

-金属A.

流体分离B.

浇口处的流体分离C.

不规则的回流AABCCCC氧化膜分布预测分析颜色代表模穴内的困气以及氧化膜分布: -金属

-含有杂质的金属Defect-Tracking表面缺陷追踪MicroPorosity微缩孔分析HotSpot热点分析以温度梯度预测最可能发生热裂的区域HPDC锌合金铸造红色区域为有问题的区域Cavitationpotential

气穴预测模拟热应力分布交流发电机外壳铸造固化过程中的热应力分布图DefectPredictionExampleslikelylocationofdefectsAirEntrainmentComparison:enginecover,A380

entrainedairoxidefilm案例说明FLOW3D能够在铸造方案设计初期进行模拟验证，从验证结果中再重新修正现有的方案设计以下将以实际案例，说明如何以金属铸造模拟系统FLOW3D进行方案设计铝合金高压铸造(A380)设计方案检验：流道设计检验、产品肉厚对于外观的影响、溢流井的位置确认充填模拟（氧化膜分布）流道系统设计检验进料速度差异造成的卷气现象修改一、进料的流道尺寸取Ｒ角，角度设计则根据模拟结果（减少流道卷气现象）修改二、调整四个进料区的尺寸大小，减少融汤在进入模穴后的卷气现象产品肉厚设计检验产品中央发生的卷气现象会在产品表面形成明显的冷接痕此处设计为一均一厚度的平板区，但是在铸造过程中，融汤的充填模式会在平板中心造成一卷气区，日后在外观上很难处理溢流槽位置定义GMO功能应用于铸造过程ColdChamberHPDC

冷室压铸HotChamberHPDC

热室压铸按一下圖片即可播放GMO功能应用于铸造过程GMO功能应用于铸造过程FLOW-3D®全球铸造企业部分用户FOXCONNTechnologyGroupChinaGangzhouPanyuTargetDieCasting&LightingCo.ChinaGuangZhouMould&DieFactoryChinaWanHoIndustrialCoLtdChinaXiamenLotaInternationalCo.,Ltd.ChinaHyundaiEngineering&ConstructionCo.,Ltd.SouthKoreaHyundaiMotorCompanyandKiaMotorCompanySouthKoreaLGElectronics,Inc.SouthKoreaLGProductionEngineeringResearchCenterSouthKoreaSamsung(S.A.I.T.)SouthKoreaSamyangCorporationSouthKoreaSeAHBesteelCorporationSouthKoreaBrotherIndustries#152JapanCanonInc#133JapanDaidoCastings#200JapanDaidoSteelCo,Ltd.#43JapanFujiElectricAdvancedTechnologyCo.,#128JapanFujiXeroxCo.,Ltd.#76JapanHinoMotors#69JapanHitachiAppliances,Inc.#242JapanHondaEngineeringCo.Ltd.#246JapanHondaFoundryCo.,Ltd.,#173JapanHondaMotorCo.,Ltd.HamamatsuFactoryJapanHondaR&DCo.,Ltd.PowerProductsR&D#226JapanJanomeDiecastingCo.,Ltd.,#178JapanMitsubishiElectric#130JapanMitsubishiFusoTechno-MetalCo.Ltd.#185JapanMitsubishiHeavyIndustriesLtd.#39JapanNikonCorp.#249JapanNipponSteelCorporation#225JapanPanasonicCommunications#88JapanRicohCo.,Ltd.#237JapanSharp#115JapanSonyCorporation#65JapanSonyCorporationEPC#182JapanToshibaCorporation#90JapanTotoLtd.#19and#222JapanToyotaMotor#169JapanToyotaMotorCorporationJapanRussia正在整理中……USA正在整理中……GMUSFORDUSEurope正在整理中……VWeuropeOthercountry正在整理中……部分论文发表08-08

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