Numerical Simulation Of The Low-pressure Die Casting Process And Fatigue Property Of Aluminum Alloys Hub Used By Automobile

Wheel is one of the most important parts in the driving system of automobile.It greatly affects the security and reliability of the car.We used to design wheels by experience.But it has many disadvantages,such as the blindness in design,the long period,the high cost and soon.The enterprises want exigent to improve the way because of the more and more intense competition.We build a platform about Design and Production of Aluminum Alloy Wheel Aided by Computer.Through Numerical Simulation,which provides the improving solution,the casting process is optimized. The preparation time for process is dramatically shortened and the cost of trial-production is reduced,saving valuable time for obtaining satisfactory percent of pass of the new model wheel.1.The conception of "Industrial Design" is applied to design the wheel.The methods and skills in the presentation of thoughts in modeling of the modeling design combine with the GB/T 3487-2005 tie the engineering technology and the presentation of artistic molding in perfectly.2.According to the process requirement of ProCAST for castings to be supplied to wheel,The basic model block and fluid analysis model block are applied to analyze fluid,temperature and stress when the casting is solidifying so as to predict shrinkage, dispersed shrinkage and other defects of these castings,being a scientific base for bogie castings manufacturing.3.Receive the residual stress of the wheel by the Stress Analysis module block of ProCAST software.Date exchange program is compiled.Node,element and the stress tensor at the node files are transmitted into ANSYS(a large-scale FEM software) using the Interface program.Then the structure of the wheel is analyzed by the structure module of ANSYS.Simulate the "initial dynamic stress" phenomenon of assambeled wheel.Through this mode,the wheel with residual stress can be analyzed when we load other weight on it.The results are more accurate than the one without residual stress.4.The structural strength is the key point to describe the quality of a wheel. Since the cornering test fails more frequently among the three,this paper applies CAE technology to analysis the structural strength under the condition of cornering test.The model of the aluminum alloy wheel is built.Stress analysis is carried out to study the influence of bolt pre-tension,centrifugal force and the cornering force to the structural as well as the distributing rule of stress and strain.To validate the result of CAE,the stress test is carried out.Compared with the collected stress,it proved that the error between them is just 4%.So the analysis model is correct and the result is credible.The research of modeling design,technique optimization,strength analysis and fatigue life prediction of aluminum alloy wheel possess versatility and practical value and obtain the huge economy benefit and engineering value in the project with an Auto company.