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以A356铝合金变速箱铸件为例,采用三维绘图软件Solidworks对变速箱进行3D造型,运用Pro CAST软件对其预定工艺的低压铸造充型和凝固过程进行了仿真。根据铸件充型的仿真结果,发现在充型过程中金属液面前沿出现参差不齐的现象。经验证分析这种现象主要是由于浇注系统设计不合理造成的。改变浇口位置后,金属液充型平稳。在铸件凝固后发现,在预定工艺中,变速箱上边缘以及浇口处产生了缩松缩孔的铸造缺陷,这是浇注温度过高引起的。根据仿真结果,进行了工艺优化,将浇注温度降低到700℃,再次进行铸造过程的仿真,发现缺陷得到了有效控制,铸件的质量获得明显改善。
Taking A356 aluminum alloy gearbox castings as an example, 3D modeling of gearboxes was carried out by Solidworks, a 3D drawing software. Pro CAST software was used to simulate the process of low pressure die casting and solidification. According to the simulation results of casting filling, it is found that the front of metal liquid surface is uneven in filling process. Proven analysis of this phenomenon is mainly due to the irrational design of the pouring system. After changing the position of the gate, the filling of metal liquid is steady. Found in the casting solidification, in the scheduled process, the gearbox on the edge and the gate has a shrinkage shrinkage casting defects, which is caused by the pouring temperature is too high. According to the simulation results, the process optimization was carried out. The pouring temperature was reduced to 700 ℃. The simulation of the casting process was conducted again. The defects were effectively controlled and the quality of the castings was significantly improved.