Die-casting Magnesium Alloys Auto Steering Pipe Column Bracket CAE

For the reason of Energy saving and emission reduction, many auto parts manufacturer begin to think about the requirement of materials choosing during the lightweight of Automobile design processing. As the lightest metallic engineering materials, magnesium alloy get the intensive interesting in resent years. In this paper, aim at manufacturing the automobile steering pipe column bracket by die casting process, we have done the following work:At first, the 3D Solid model of the automobile steering pipe column bracket was build by using a drawing software. The cross-section of sprue, runner and ingate were calculated, according to the calculation results three different gating system of the automobile steering pipe column bracket were designed. The filling process were simulated using Flow-3D software. The better filling system was chosen according to the simulation result by using the surface defect and the volume of gas as a criteria.And then orthogonal test method was used to optimize 9 groups of process parameters, which were consisted of pouring temperature, mold temperature and injection velocity. After simulated by using Flow-3D software, the relatively satisfactory results of AZ91D are as follows:pouring temperature with 720℃, mold temperature with 210℃and injection velocity with 2.3m/s can obtain a minimum volume of gas, and pouring temperature with 680℃, mold temperature with 220℃and injection velocity with 5.7m/s can obtain a smaller percentage of surface defects. It is therefore clear that pouring temperature with 680℃, mold temperature with 220℃and injection velocity with 4.5m/s are the optimal process parameters.After the theoretical calculation and numerical simulation of the die casting process of manufacturing the automobile steering pipe column bracket, the optimal process parameters of the slow injection process are accelerated speed with 0.6m/s² and slow injection speed with 0.4m/s. In order to improve mold life, 2 groups of cycle waterways were designed. The mold temperature and cavity wall temperature of group B is 40% of pouring temperature. At the same time, the temperatures of group A are higher. The mold energy fluctuation of group B ranges from 6.5×10¹²J to 9.1×10¹²J, which is smaller than that of group A from 9.4×10¹²J to 6.5×10¹²J. It turns out to be that group B is more reasonable than group A to reach thermal equilibrium.In this paper, the simulation results of manufacturing the automobile steering pipe column bracket by die casting process can achieve the goals of shortening the development cycle, saving the development costs and improving the product quality.