Simulation Analysis And Process Design Of Cylinder Head Cover Die-casting Process

Cylinder head cover is one of the important parts in the automobile engine system,it can keep the oil inside,dirt and moisture outside the cylinder while the engine is working,.For this product,it not only need to get the higher surface quality,but also need to meet the requirements of mechanical property.In this research,in order to solve the problem that the present production of 1.3t cylinder head cover yield is low and process defects exists in Guiyang Guanghang Casting Co.,Ltd.the mould design,process parameter optimization,forming defect analysisare included in this thesis.The cylinder head cover model building is after the structural characteristics analyzing.Considering the clamping force of die-casting molding results in the process and the actual conditions of the factory,the DC1250 horizontal cold chamber die casting machines are used.Based on analyzing the pressure casting process for cylinder head cover mould,the parting surface is selected;the direct sprue,runner and gating system for cylinder head cover are designed and calculated;the casting of the overflow system and exhaust system position are arranged and the size and shape are designed.It shows that the original production plan is easy to appear excessive local defects such as air pressure,because of bad filling or air trappingby using the die casting process simulation software Anycasting schemes analyze the original process for cylinder head cover in production.By improving the structure of the die casting overflow box,the filling sequence is optimized,and the air pressure is decreased in the part of casting after add the overflow box.Based on the residual melt modulus,analyses distribution of the probability defect parameters of each section of cylinder head cover,forecast the distribution location where easy to appear porosity shrinkage.In order to obtain the optimizing process parameters combination,it use pouring temperature,distance of slow/fast injection and the speed of injection as three factors,in the three factors orthogonal experimentize to optimization the die casting process parameters.By comparing the size of each scheme about residual melt modules,judging the distributing of probability defect parameters,and getting the best die casting technology scheme,the pouring temperature is 630 ?,the slow/fast injection distance is 700/160 mm,the injection speed is 6 m/s.Compared with the original process the casting filling and solidification time are reduced,the residual melt modulus decreased at the same time,also with residual melt modulus to determine defects of probability parameter value decreased,and the defects such as shrinkage cavity,shrinkage porosity are reduced in the new process based of the optimal parameters.Meanwhile the production process route of the cylinder head cover parts are designed,the process parameters are selected,the die casting parts are reprocessed.By using the optimization of casting simulation software,cylinder head cover parts yield is improved,the production time is saved.This topic has great practical application value and significance.