Study On Squeeze Casting Mold Design And Application For Large And Complex Parts

In recent years, with the development of automotive, rail transportation and aerospace industry, the demands of high property and large parts increase dramatically. In order to adapt the requirement of components lightweight and high performance, aluminum alloy squeeze casting has been used more and more widely and attracted more attention in market. For large parts squeeze casting forming, due to its large size, complicated shape, non-uniform wall thickness and forming difficulties characteristics, it is difficult to meet the forming demand by using direct squeeze casting or indirect squeeze casting separately. So, it is necessary to develop novel squeeze casting forming technology for large and complex parts, and it has important significance for the promotion and application of squeeze casting technology. With a large and complex parts as the mainly object, this paper undertook a series of researches on squeeze casting mold design and application.Firstly, forming technical features of squeeze casting for large and complex parts were analyzed. O n this basis, the forming method and squeeze casting mold for the large and complex parts were developed. Pro CAST software was used to simulation and analysis of flow field on casting, and the results provided the reference and basis for the squeeze casting mold design.Furthermore, the key problems in the squeeze casting processes for large and complex parts were studied. On this basis, a squeeze casting mold structure for large and complex parts was developed. According to the strength performance of the mold, the static analysis of the mold under ultimate load was simulated by using Mechanical model based ANSYS Workbench software, the main parts strength is verified and the main parts deformations are analyzed. The results show that the deformation and strength of the mold components satisfied the requirements of squeeze casting for large and complex parts.For the special requirements of the mold structure for large and complex parts, rigid- flexible coupling dynamic model of squeeze casting mold was established by using coupling modeling method based ANSYS-ADAMS software. The stationary of upper mold and the vibration of mold core were simulated by ADAMS software under five different stress conditions(0 k N, 100 k N, 1000 k N, 3000 k N, 5000 k N). The results of dynamic simulation show that the squeeze casting mold can work smoothly, either in weight or in driving pressures, the squeeze casting mold movement characteristics were meet the design requirements, and the mold structure was suitable for forming process.The squeeze casting mold for large and complex parts was manufactured according to the above design, and forming experiments for large and complex bracket part are conducted using A356 aluminum allo y material, and the weight and size of the products are meet the design requirements. The results show that the squeeze casting mold structure is reasonable and the mold movement is feasible, and and the effectiveness of the mold and the forming process for large and complex parts were verified.