4004 Aluminum Silicon Alloy Rolling Hole On Defect Simulation And Experimental Research

Silicon of 4004 Al-Si alloy is the main alloying element.4004 Al-Si alloy has good performance and is widely used in automotive industry and air conditioning industry,and since it has good liquidity,and low melting point,is widely used in aluminum foil manufacturing industry.However,since silicon content of 4004 Al-Si alloy is higher,the material of the plastic deformation ability reduces,gas porosity and other defects generate in the casting process.And these defects extend further in the rolling process,which reduce mechanical properties of alloy and affect the product quality and safety of using.Currently,domestic production is mainly based on past experience modulation process.And this problem can't be solved accurately.This paper uses ANSYS finite element software,researches the influence of different rolling process(temperature,reduction,rolling passes)for defect through numerical simulation of software based on microscopic damage theory,analyzes combined with rolling experiment,obtains the influence rule of rolling process for gas porosity and other defects,provides a set of rolling process to resolve the technical problems.The main contents are as follows:Firstly,according to the generation principle of gas porosity,analyzes the reasons that gas porosity generates in process of Al-Si alloy casting,explores solution of gas porosity defect completely.Secondly,studies microscopic damage theory,researches the variation for gas porosity defect of Al-Si alloy according to the specific circumstance of rolling process.Finally,microscopic damage model is established for the accuracy of numerical simulation.Firstly,according to the force and kinetic characteristic of the rolling process,analyzes the influence of every parameter for gas porosity in the rolling process based on ANSYS software.Secondly,establishes rolling system and gas porosity model of Al-Si alloy,sets the boundary conditions and designs a variety of different process parameters according to practical production condition: press quantity,temperature,rolling speed,rolling pass.Finally,calculates the influence of various process parameters for the stress and dimension of gas porosity.Firstly,selects a series of rolling process parameters preliminarily based on the early work,rolling experiment is done.Secondly,changes different process parameters(pressure,temperature,rolling pass and rolling speed)and observes microstructure of rolled piece,then determines the optimal rolling process.Finally,combines with variation of gas porosity defect summarized by early work,finishes production process improvement according to theoretical research.This paper,according to the numerical simulation technology,combining with the theoretical and experimental research,analyzes the variation for stress and dimension of gas porosity in Al-Si alloy under different process parameters.Then achieves the purpose of optimizing process parameters and provides guidance for practical production.