The Development Environment Of The Wheel Mold For Low Pressure Casting Of Al-alloys On Magmasoft

With the rapid development of the automobile industry, the structure and appearanceof the wheels almost is updated in every car model. So reducing the wheel develepmentcycle time has a positive effect to shorten the car model update time. In the wheeldevelopment process, manufacturing process development has a direct impact on thewhole development process. Low pressure die casting is still the main process forproducting aluminum car wheel, and experience is the main approach for low pressurecasting mold design, which uses long cycle time. So it can’t meet the car developmentrequirements.In this thesis, the traditional approach for aluminum wheel production and thedevelopment method for low pressure casting mold were introduced, and castingsimulation used Magmasoft was adopted for the mold design and process optimization inthe early development. According to the actual wheel production enviroment, whichincluded production process and mold cooling system, in order to make the uniformitybetween simulation conditions and actual production conditions, the boundary conditionsfor casting simulation in Magmasoft were studied, the mold cooling and exhaust systemare improved.Then, the compatibility between the simulation boundary and the mold improvementwas proved, the mold temperture between simulation and actual were compared. Finaly,Magmasoft was used to deal with the practice wheel problems based on the frontmodification, and the problems were solved according to Magmasoft casting simulationresults.As the effect of the actual production verification shown, the modified boundaryconditions can match well with the structure of the modified cooling system. The castingwheel quality can be improved by using the Magmasoft in the mold improvement. So, inthe early time of the LPDC wheel development, the optimization of mold design whichused Magmasoft casting simulation is validity to short the wheel development cycle time.