Research On Numerical Simulation Of Die Casting Of Aluminum Alloy Die Castings

Because die casting aluminum alloys have good performance and processing properties, the development of its industry is very fast and wildly applied in varies industrial sectors. By numerical simulation method of aluminum alloy die casting forming process of mold filling and solidification, it has great significance in improving the process design level, ensuring the quality of die castings and increasing productivity.By using casting numerical simulation software ProCAST, combining the basic theory of mold filling and solidification, analyzing the numerical simulation result and predicting porosity, shrinkages defects appeared in the die castings, in order to optimize die casting process parameters, establish reasonable technical programs, meet the needs of enterprise production. There are several researches in this paper, as follows mostly:1. ProCAST hasn't CAD modeling system, so use UG NX4.0 for three-dimensional solid modeling. Analyzing two graphical date exchange standards between UG NX4.0 and ProCAST software, doing date exchange of the comparative experiments, so determine PARASOLIDS format used for data transmission. Reasonable die casting numerical simulation flow process is established.2. In accordance with the characteristics of the disc die castings, numerical simulation tests of die casting combined with empirical date have taken to build the appropriate gating system. Combining the actual situation set up by analog necessary thermo-physical properties of materials parameters and die casting process parameters, the pre-treatment of simulation has finished. From the results of simulation, the flow field, temperature field, solidification states are analyzed and the porosity shrinkage defects site in the product are predicted.3. Many groups of numerical simulation tests about die casting process parameters are taken, through analysis of flow field, temperature field, and defects prediction from mold filling and solidification results, at last the best die casting process parameters is got.4. Do numerical simulation experiment about mold filling and solidification of non-uniform wall thickness of cylinder die casting, defective parts is predicted. The actual casting and simulation results are basically consistent that manifest the reliability of numerical simulation carried out at ProCAST, provide scientific guidance to process design and die casting parameters conform.5. This paper has carried out flow field-temperature field coupling analysis of die casting mold filling and solidification process, but without stress field coupling. Follow-up work can take flow field-temperature field-stress field coupling calculation, and further improve the accuracy of numerical simulation.