发动机活塞裙铸造过程模拟及工艺优化

目的优化发动机活塞裙铸件铸造工艺。方法采用UG等软件设计活塞裙铸件浇注系统以及采用MAGMA铸造仿真软件对铸造工艺进行仿真预测,分析铸件凝固温度场,预测缩孔、疏松等铸造缺陷,进一步优化铸造工艺。结果铸件整体上实现了自下而上的顺序凝固,虽然通过冒口获得了一定程度的补缩,但凝固温度梯度不明显,冒口疏松缺陷依然延伸至铸件上端面。通过合理设置冷铁,增加冒口和内浇口数量,从而实现铸件顺序凝固,使补缩效果更为明显,可有效降低缩孔、疏松缺陷。结论采用MAGMA铸造仿真软件分析凝固过程并预测缺陷,通过改进和优化工艺,可以有效预防活塞裙铸件缺陷的产生,提高铸件合格率。

Casting Process Simulation and Optimization of Engine Piston Skirt

The paper aims to optimize the piston skirt casting process of engine. The casting system of piston skirts was designed by software such as UG and the casting process was simulated by MAGMA casting software to analyze the solidification temperature field of casting and predict casting flaws such as shrinkage cavity and porosity, to further improve the casting process. The results showed that the casting solidification as a whole was congealed from bottom to top. Although feeding was achieved by dead head, the temperature gradient of solidification was not obvious. Rarefaction defect of dead head was stretched to upper end surface of casting. By reasonable setting of chilling block, quantity of dead head and flow gate could be increased to achieve casting solidification in sequence, realize obvious effect of feeding and significantly reduce shrinkage cavity and porosity defect. MAGMA casting simulation software can be used to analyze solidification process and predict defect to effectively prevent casting defects and improve the qualification rate of casting by optimization and improvement of process.