The Research Of Die-casting Process And Numerical Simulation Of Steering Gear Shell

The steering gear shell plays an important role in automobile redirector assemblyparts which is class D security. The casting not only requires a higher surface quality butalso achieves a certain degree of mechanical strength. Controlling the quality of steeringshell part has been a technical problem in the casting industry. The key to control thequality of the products is how to design the casting pouring system and choose theparameters of die-casting process. The numerical simulation and experiment validationgive a support to Chongqing qianheng machinery manufacturing which has a low yield inthe die casting shell of S30050.In this paper, with the help of simulation software which is called Anycasting, westudied the influence of gating system to the casting quality.According to the differentfilling and solidification conditions, we gain the best gating system for shell parts diecasting of S30050. Basing on the best gating system, we designed the orthogonalexperiment.We used the residual melt module and the defect area as the quantitativeparameters to do the experiment. At the same time, the influence of the three processparameters to the quality of the die casting shell was studied. On the basis of analysis ofcasting process, we designed the important forming part which include the ejectingmechanism the reset mechanism and the mold cavity. Through the processing of theproduction，the product was tested and analyzed.The research results show that the factors which have the influence to the quality ofthe product are mould temperature, initial filling speed, pouring temperature. We canconclude that with the increasing of the factors, the probability of the defect parametersincreases first and then decreases, the optimal value is generated in an intermediateposition. Through the analysis of orthogonal test, the best parameters of die casting processare got. Pouring temperature is about670℃, the filling speed is about2m s-1, the initialtemperature of mold is about200℃. In this condition, the liquid of aluminum alloy fillcompletely in the casting mould and the distribution of temperature is reasonable. Thecastings achieve the sequence solidification basically. After the optimization of thetechnology parameters, the probability defect parameters of the product are decresed to thelowest. There is still a small range of defects. After actual die-casting testing the castingshas no obvious defects on surface and mechanical properties. Such as tensile strengthreached the expected goal, defects in small area are controlled which have no affecting the performance of castings.Compared with the actual casting, we find that the area of defect was consistent withactual castings’ defect position area. It is illustrated that the software of casting simulationcan have the effect on optimization in the die casting production. According to the actualproduction of die-casting, the result is corresponded to the theory.So the studying of theorycan be applied directly to the factory. Through the optimization of the casting simulationsoftware, the production cost is reduced, the cycle of trial production is shortened, and theyield of the product is improved.