Structure Design Of Aluminum Alloy Wheelhub And Study On Counter-pressure Casting By Means Of Finite Element Analysis

Based on aluminum alloy wheels used on automobiles and special vehicles,and on analyzing fluidity and molding of aluminum alloy melt by counter pressure casting, simulation has been established for molding process of aluminum alloy wheels.According counter pressure casting technique and structure of aluminum alloy wheels,designing of molding system and optimized mold has been discussed.Finite Element Analysis has been done on automobiles and special vehicles,using A365 alloy and ZL205A for automobiles and special vehicles respectively,and Physical and Chemical Detection and property testing has been finished on sample.The results of this study show:Under the state of counter pressure casting,simulation on temperature field and on stress field by software Magmasoft v4.2,and observing process of aluminum alloy melt floating and phase changing provide technique bases for optimized designing on counter pressure casting technique.Application of appropriate molding system and mold designing,is the key of technique on realization of aluminum alloy wheel molding by counter pressure casting,and of enhancing quality of casting's inner parts.Comparing with low pressure casting,by counter pressure casting,tensile strength and tensility ratio of ZL205A are increased by 10.2%and 16.7%,respectively.Tensile strengthand tensility ratio of ZL114A are increased by 6.7%and 65%,respectively.For aluminum alloy melt with counter pressure casting,application of plasma refining technique can reduce air content and impurity content in aluminum alloy melt.Application of Sr transformation technique can change Eutectic Si grains from rough needle shape or board shape into tiny shape.The results of Finite Element Analysis show that under 9800N load,the maximum stress of automobile aluminum alloy wheel is 152Mpa,which is less than yield strength(205Mpa) of ZL101 aluminum alloy.Under 127000N load,the maximum stress of special vehicle aluminum alloy wheel isl64MPa,which is less than yield strength(255 Mpa) of ZL205A aluminum alloy.Sample aluminum wheels of automobiles and special vehicles by counter pressure casting,have a compact microstructure inner,with fine grains,without air holes,and with no loosen.Tensile strength of sample automobile A356 aluminum alloy wheels made by counter pressure casting is 290Mpa,with tensility ratio of 6%.Tensile strength of sample special vehicle ZL205A aluminum alloy wheels made by counter pressure casting is with no heat crack,loosen or other defects.