The Research And Application Of Aluminum Alloy Die Casting Technology And Virtual Process Optimization

Aluminum alloy which is widely used in aerospace, light industry, building materials,transportation and other industries is the largest amount of non-ferrous metal structure materialin die casting industry. Die casting technology is a kind of special casting, and it has beenapplied more and more widely because of its high filling capacity, high production efficiency,capable of casting net shape or near net shape forming. However, most die casting enterprisesstill use the traditional die casting process which is based on experience repeatedly to ensure thequality of the die casting, resulting in the entire production cycle extended and the cost increase,especially for the complex structure die casting. Because of the impact of high speed and highpressure, it is difficult to predict the flow process of molten metal, and it is easy to produce coldshuts, volume gas, and misrun defects, affecting the yield of the product and erosion mould.This paper studied on an defective part of automotive aluminum alloy cylinder which wasprovided by cooperator. By using p-Q~2technology, numerical simulation technology and robusttheory, the die casting process which contained reasonable structure and the most stable qualityof die casting had been gotten, and the purpose of reducing the test time, ensuring products’quality, guiding practice had been gotten.Firstly, the p-Q~2drawing auto system programmed by Visual Basic, it can solve thetechnology difficulty of the match between die casting mould dimension, filling speed and fillingpressure. Secondly, the defects produced by original die casting mould were analyzed throughthe numerical simulation, and then the improvement solution was proposed. Thirdly, theimprovement solution was also simulated, so the Exhausting System of die casting mould wasoptimized more. Base on the optimal solution, the robustness of the mould was analyzed byTaguchi experiment. Every group of parameter’s filling process under the effect of noise factorwas observed. And the result which was targeted as shrinkage and shrinkage porosity was got.Then the signal-to-noise ratio was calculated based on smaller-the-better characteristic, so theoptimal parameter group which was not sensitive to noise factor and so can prove the quality ofdie casting can be achieved. At last, the optimal parameter group was applied to produce.The results show that, when injection speed is3.3m/s, pouring temperature is670°C, moldtemperature is280°C and heat transfer coefficient is1100W/m~2·K, the quality of die casting isthe stablest. Through the verification of production practice, the virtual experiment results of thisset of parameters coincide with the actual production. The die casting’s quality was excellent andits dimension is precise, all of that can meet the requirement of produce.