| In recent years, as the development of automotive industry becomes more mature,vehicle production increased sharply. But automotive industry consumes a lot ofenergy, while environmental crisis are rising in recent years. Competition in theautomotive industry is gearing towards the development of new energy. The futuretheme of automotive development will be Energy saving and environmentalprotection. Due to magnesium alloys offers a lot of advantages such as low-density,low-cost, high-specific strength and high-stiffness. The application of magnesiumalloys in the automotive industry is becoming more and more important with a hugespace for development. It will be a great challenge to the processing technology ofmagnesium alloys. Die-casting that is pressure die casting is a method which underhigh-pressure forces the molten alloy liquid to be poured into the pressing room,filling the cavities of steel molds and solidifying to a casting under high speed.Compared with other casting method, die-casting has advantages such ashigh-pressure and high-velocity, and the time of the whole processing is very short,about0.01-0.2s. The casting product formed by die-casting is of good quality, highproduction efficiency, and have excellent economic effect. Die-casting is one of themost advanced metal casting methods currently in use, the utilization of die-castingon magnesium alloys processing is the focus of current research. Die-casting is one ofthe most advanced metal forming methods, the current trend is focusing on applyingdie-casting in the process of manufacturing magnesium alloys. As die-casting isconducting filling under high pressure with high velocity, gas can be easily caughtinto the mould, only can be partially evacuated through vent and overflow, as a result,the possibility of having flaws like shrinkage cavity appears in the casting increasesconsiderably. The possibility of defects will dramatically increase, especially, when castings have more complicated structures, or relatively wide alloy crystallizationtemperature range. Using ProCAST to simulate the filling and solidificationprocedure of casting can effectively predict the forming and position of defects suchas shrinkage cavity, thus improve casting technique conditions, ultimately guaranteesthe quality of the casting. Also, comparing to the traditional research and developmentprocedure, the application of mathematical simulation is proved to be more accurateand leads to the reduction of the required research period, thus the productionlifecycle is shortened and the manufacture process cost can be less, increase the profitof production. It can provide the basis for the entire production process.In this paper, HyperMesh which is advanced in the world，is used as thepre-processing software. It offers wide interface with other CAD and CAE software.Three-dimensional CAD model and finite element model can be imported into itdirectly. It also can clean and optimise the model conveniently and flexibly, thenestablish finite element mesh efficiently and effectively through mesh generation toolswith efficient finite element processing. This study use HyperMesh to modify thegeometry, model of magnesium alloy oil pan, divide and modify the surface andvolume mesh, thus lay a good foundation for the ProCAST numerical simulation.Export the file named as.out from HyperMesh, and imported it into the softwareMeshCAST, divide the volume mesh and save the file as.mesh format, then import itinto the PreCAST to set up the simulation parameters. Here, we use virtual model tosimulate. In the forming simulation of oil pan, analysis of the defects, such asshrinkage cavity and porosity of the casting, further more, optimization of the processparameters to be a process parameter, defects such as wrapped gas and shrinkagecavity are fewer than normal, and filling is more completed. In addition, solidificationtime is decreased, so it is suitable for the actual production process. |
PDF Full Text Request