Low Pressure Die Casting Molding Process Simulation Of Large Aluminum Transmission Case

Molten metal is filling up the casting along the lifting tube from down to up under the gas pressure is called low pressure die casting. The molten metal is always under the gas pressure when it is solidification. This casting method is predominant than other methods. In this study, Low Pressure Casting Metal is used, under this improved casting method, the casting have high surface finish quality easy to machine; Use less molding materials, make less pollution. Manufacturing procedure is easy to achieve mechanization and automation. But the metal casting is not widely used because of the high coefficient of heat transfer of metal, hard to achieve the directional solidification.The casting in this study is a part of the UHV substation called transmission case made by aluminum. The weight of the casting is 270 kilograms. The wall thickness is 15 millimeter and 260 millimeter, so it hard to design and production. Based on the analysis and comparison on the mounding technique and structures technology, a transmission case is designed. Based on the gating system including sprue, cross gate and ingate, numerical simulation is used for fixing the technological parameters. The technological parameters are speed of mold-filling at 0.5m/s, pouring temperature is 700℃and mold temperature is 220℃.According to the result of computerized numerical simulation, analysed the feature of solidification, to design the cooling system to optimize the solidification process of the temperature field, reduce the casting defect. The result is used in the production. The casting was checked and accepted, proved the correct parameters. numerical simulation used into actual production, optimized the production process, reduced production costs and production risks, with a minimum investment to the maximize revenue, increase the market competitiveness.