Research On Design And Forming Simulation Of Automobile Trunk Cover Plate Based On Die Casting Technology

With the development of die-casting technology,aluminum alloy integrated diecasting technology has begun to be applied to large components of automobile bodies.Traditional automotive body panels are composed of inner panels,outer panels,and reinforcing components through welding or riveting,which results in cumbersome and time-consuming forming processes and low material utilization.This project takes the automobile trunk cover plate as the research object,and combines the design criteria of die-casting and the design specifications of trunk cover plate to carry out an integrated design of trunk cover plate.The bending resistance,torsion resistance,dent resistance,modal performance analysis,and performance optimization are carried out on it.Perform die casting simulation on the optimized performance of the automobile trunk cover plate,and analyze the simulation results.The influence of internal gate on the flow of metal liquid,the relationship between die-casting process parameters and air pressure,as well as the degree of mold erosion,were studied,and a satisfactory automobile trunk cover plate and its optimal die-casting process parameter combination were obtained.The main research work and achievements are as follows:(1)Analyzed the current application status of automobile trunk cover plate,diecasting technology,and die-casting technology,and designed,modeled,selected materials,and simulated the die-casting automobile trunk cover plate.Through the analysis of the current situation,it was found that applying die-casting to large thin-walled parts such as car body panels has certain research significance.Combining the design criteria for die-casting and the design specifications for automobile trunk cover plates,the design and modeling of integrated automobile trunk cover plates were carried out with reference to traditional automobile trunk cover plates.Select aluminum alloy material as the material for the integrated trunk cover plate based on the requirements of die-casting process and mechanical properties.On the basis of the designed integrated automobile trunk cover plate model,die casting simulation was conducted,and the results showed that the mold could be fully filled,verifying the feasibility of the design scheme.(2)The mechanical performance analysis,structural optimization and lightweight treatment are carried out for the designed integrated automobile trunk cover plate: the static mechanical performance analysis and the constrained mode and free mode dynamic mechanical performance analysis are carried out for the automobile trunk cover plate under the upper and lower stress conditions,lateral stress conditions,torsional stress conditions,and nesting conditions.Based on the unqualified working conditions,the morphology optimization was carried out to obtain the layout position of the reinforcing ribs.Based on the design criteria for reinforcing ribs of die-casting structural components and considering the flow of die-casting liquid,the reinforcing ribs of the die-casting automobile trunk cover plate were designed.Mechanical performance analysis was conducted on the trunk cover plate with reinforcing ribs,and a trunk cover plate with reinforcing ribs that met the requirements was obtained.On this basis,lightweight treatment was carried out,and topology optimization was used to obtain the installation position of accessories and reduce the weight of the automobile trunk cover plate by8.40%.Compared to traditional automobile trunk cover plate,the weight of the aluminum alloy integrated automobile trunk cover plate has been reduced by 20.00% to 30.00%,and the mechanical properties of the lightweight automobile trunk cover plate still meet the requirements.(3)Die casting simulation analysis was conducted on the integrated automobile trunk cover plate,and the structure and process parameters of the die casting pouring system were optimized.The filling process and solidification process of the die casting were analyzed.By analyzing the flow of metal liquid during the die casting process,the optimal angle of incidence of the inner gate was obtained.The influence of process parameters on air pressure and mold erosion was studied using orthogonal experiments.The optimal process parameter combination for the die casting of the automobile trunk cover plate was obtained using a single factor optimization test method: mold temperature220.00 ℃,pouring temperature 640.00 ℃,low speed injection speed 0.70m/s,and high speed injection speed 4.00m/s.