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采用Procast软件基于PLCO粘度模型建立了半固态挤压铸造工艺成形空调压缩机铸铁曲轴的数值模拟模型,并获得其合理工艺参数为:坯料浇注温度1165~1185℃、模具预热温度300~400℃、冲头充填速度0.05~0.25 m·s-1。模拟结果表明,浇注温度过低或冲头速度过低时,不能完整填充型腔;冲头速度过大,充填型腔中浆料发生湍流现象,容易卷气;铸件凝固时间随着模具温度的升高而升高,但是过高的浇注温度或模具温度容易使零件产生缩松缩孔缺陷;对半固态挤压铸造工艺和液态挤压铸造工艺进行分析比较,发现半固态挤压铸造成形可以避免液态挤压铸造成形工艺中存在的卷气严重、不能实现顺序充填和热节较大等缺陷。
Procast software was used to establish the numerical simulation model of cast iron crankshaft of semi-solid extrusion casting process based on PLCO viscosity model. The reasonable process parameters were as follows: billet pouring temperature 1165 ~ 1185 ℃, mold preheating temperature 300 ~ 400 ℃ , Punch filling speed of 0.05 ~ 0.25 m · s-1. The simulation results show that when the pouring temperature is too low or the punch speed is too low, the cavity can not be filled completely. When the punch speed is too high, the slurry in the filling cavity is turbulent and easy to get angry. The solidification time of the casting increases with the mold temperature However, too high pouring temperature or mold temperature tend to cause shrinkage and shrinkage defects in the parts. Analysis and comparison of the semi-solid extrusion die casting process and liquid extrusion casting process found that semi-solid extrusion die casting can be Avoid liquid squeeze casting forming process exists in the serious curly, can not achieve sequential filling and larger heat and other defects.