Low Pressure Die Casting Mold Design And Process Verification For Engine Aluminum Alloy Cylinder Head

Low pressure die casting is an important process of aluminum alloy die casting for automotive manufacturing industry with the advantage of high precision,smooth filling,easy to make high quality casting and small machining allowance,saving energy etc.which has been the development trend for Cylinder Head casting industry.In China,as Low Pressure Die Casting for Automotive Aluminum Alloy cylinder head is still in the initial step now,and the theory and technology for Low Pressure Die Casting Aluminum Alloy cylinder head is not very maturity.So there will be important value for engineering application to perform the study on aluminum alloy cylinder head low pressure die casting process and technology,and also for our country automotive industry rapid development.Based on the low pressure die casting solidification theory,this article studies cylinder head low pressure die casting mould design,casting filling process and solidification process simulation with mold CAD and CAE technology.First,design cylinder head tooling structure and casting process system considering low pressure die casting character and cylinder head structures as well as its quality requirements.The content are including:tooling overall structure definition,tooling parting surface definition and the outer tooling dimensions definition principle,the relation between tooling wall thick and tooling thermal equilibrium casting pouring system setting up,inner gates section surface calculating,cooling system design,several kind venting methods application and the sand core location design,sand core shooting gate definition and so on.Then,based on low pressure die casting filling and solidification basic theory,inputting the cylinder head model into Anycasting simulation software to do the Finite-Difference mesh subdivision,setting up the process parameter and pressure curve,and then simulate the filling process and solidification process for low pressure die casting cylinder head.The filling time is 15 seconds and casting solidification time is around 350 seconds.Meanwhile,this article also simulates the outer mould temperature distribution field,which meets the progressive solidification requirements of low pressure die casting.Predicts the potential casting defects location and make the corresponding analysis. Optimize or improve the cylinder head mould structure or casting process system based on the simulation results,and resolve the shrinkage hole and micro-porosity defects around the casting gate thick areas.Finally,this article introduces Al-alloy cylinder head low pressure die casting actual production processes,such as sand core making,melting,pouring, cleaning and post-treatment,as well as the main problems in each process. Raise the key quality control points for Al-alloy cylinder head low pressure die casting,such as:the reasons for shrinkage holes and porosity and its solutions, as well as oxide inclusion.This article solves the difficult problem during the production and provides the data and experience for later other die casting product developing to shorten the development lead time,which make this product enter into the mass production smoothly.