Numerical Simulation, Parameter Optimization And Utilization For Die Casting Process Of Step

The numerical simulation of step aluminum alloy die casting mold filling process was carried out at the same parameters by use of ProCAST software. Optimal parameter combination was obtained by experimental result analyses and optimization of die casting processing parameters. The study includes the following aspects:1.In the first chapter, structure analysis was done to step parts using finite element software I-Deas. The weight of step parts was reduced based on the force bearing magnitude of step different structures to ensure the safety of elevator. However, the thin wall thickness after weight reduction makes it hard to form and the subject is introduced.2.In chapter 2, theoretical model used in this numerical simulation and the software ProCAST used were introduced from the perspective of computational fluid dynamics and heat transfer.3.Chapter 3 gives a brief description of die casting theory and a new die casting method. Besides, three-dimensional model of step parts gating system was designed by UG,including the design of sprue, runner, ingate and the distribution of overflow。4. In chapter 4, the three-dimensional model in Parasolid format was imported into ProCAST, then painting grid and setting the corresponding boundary conditions in ProCAST. Three important factors affecting casting were selected, they are mold temperature 190℃,pouring temperature 620℃and filling speed 5m/s separately, and choose three levels in each factor, design orthogonal test to numerical simulation, and analysis of the test results to obtain the optimum parameters finally.5.In chapter 5,numerical simulation analysis the optimal process parameters, which obtained on the last chapter, shows that this set of parameters can reduce the wrapped gas, oxide inclusions, casting defects such as shrinkage porosity. Finally, verify the actual production, simulation results coincide with the actual production, and the steps to produce the mechanical properties of parts were tested to meet national standards for the safe use of elevators.