Low Pressure Die Casting Numerical Simulation Of 4G93SD4 Cylinder Head And Process Optimization

Due to high size precision, smooth mold filling, controlled mold fillingvelocity and easily gained non-defect cast, the low pressure die casting is animportant technology to produce Al alloy automible cast. Cilinder head diecasting has becamed the trend of Automible cylinder head casting, and willgradually replace gravity casting. In China the low pressure die casting toproduce cylinder head has just started, it did not have the theory and technologyof the mature independent intellectual property rights on the low pressure castingto produce the cylinder head. Thus the research on the low pressure casting toproduce Al alloy cylinder head has the important project application significanceand the theory academic value.The paper aims to Japanese 4G93SD4 cylinder head that is the importantpart of 4G9S3 gasoline engine, low pressure die casting solidfication process:Simulation is studied by Anycasting software on the basic of the characteristicsdie casting solidification, and the simulation is based on the three-dimensionalmold of the cylinder head. After the three-dimensional mold has been designed, itwas inputed in the Anycasting software, the finite difference has been carried onthe cylinder head by the grid difference function. Reasonable runner system bypractical applications ascertained, which are validated by practical applications.The problem has been found in the existing method, and the research wascarried on the eliment which influenced the quality of the castings assisted bymathematical simulation, Such as the pouring temperature, the increase ofpressure, solidification pressure ect.. Then the optimization on the exsitingmethod was carried out, and the reasonable runner system and parameter wereascertained. Finally this article carried on the production confirmation, introducedtechnological process to produce the 4G9 low pressure die casting cylinder head.And the paper carried on the outward appearance quality and the intrinsic qualityanalysis to the 4G9 low pressure die casting cylinder head casting whichproduced has. The result pointed out: the casting does not have coldshut and thepouring insufficient flaw; the outward appearance quality may satisfy the productrequest. The interior exist the shrinkage hole, shrinkage porosity and the crackdefect. The result of simulation matches to the pratical production. The researchhas the important significance including the explorment of other cylinder head,and amassed much experience and data, avoid going wrong. It has a greatmeaning to solve the real problem in the practical production.