Die Casting Process And Numerical Simulation Of Aluminum Alloy Cylinder For Automobile Engine

With the awareness of environmental awareness increasing, and oil energy is non renewable, to solve the series of problems of coping environmental pollution, contradiction between the demand and supply of fuel oil and reduce fuel consumption,requirements for automobile castings should not only have strong toughness, but lighter quality, and green environmental protection and other characteristics. Cylinder is the core component of the engine, using aluminum alloy material in the production, can reduce the weight of the engine, and ultimately achieve the purpose of reducing the weight of the whole car. For the production of engine block, there are three main casting processes: gravity casting, low pressure casting and pressure casting. And in the process, compared to the low pressure and gravity casting, pressure casting technology is not only a higher productivity, but also can produce a variety of complex shape of aluminum magnesium alloy products, casting precision, strength and surface hardness are relatively high, has been widely applied to automotive, aerospace, electronics and other industries. Therefore, this project uses the pressure casting technology to carry on the research.The process features of the engine block are: the shape and structure are complex; the plane and the hole are more; the machining precision is high and the wall thickness is uneven, which belongs to the very typical box processing parts. In this paper, the structure of the engine block is analyzed, the casting process is designed, the pressure casting parameter setting and the process verification are studied according to the combination of the pressure casting and the cylinder’s own characteristics. Mainly include: the casting system, mold filling process, solidification process numerical simulation, predict the possible casting defects, so as to determine the reasonable process and other content.This topic according to the basic theory of mold filling and solidification process of pressure casting. First of all, the cylinder model import of casting simulation software, and then design the orthogonal experiment method to optimize the casting process. In the casting simulation, first divided the casting model into grid partition, design different ingate sectional area to study the influence of shrinkage porosity and shrinkage porosity of the castings, determine the optimum ingate area. Redesign the orthogonal experiment to the casting simulation and analysis, and predict the location of the casting defects,and then study the obtained results by mathematical analysis of range and variance analysis, according to calculating the corresponding analysis, to obtain the best casting process parameters, and ultimately determine the engine cylinder forming process simulation and optimization scheme, namely: the ingate area is 6.5x103mm2, the injection speed is 6m / s, the liquid metal pouring temperature is 680℃,the mold preheating temperature is 240℃.