Design And Production Validation Of 1-Mold-2-Casting Of Aluminum Cylinder Head By Low Pressure

Low pressure casting technology(LPCT)is a special casting technology,which is based on the Pascal's law.The characteristics of LPCT lies in that the metal liquid fills stably from bottom to top in the mold and frees in high pressure under pressure differences between crucible and cavity gas,and it can avoid the forming of oxidizing slag and improve the feeding efforts to get the casting compacted and the mechanical properties refined.The research development of the LPCT is reviewed.The aluminum alloy cylinder cover mold is designed with two cavity.Through the casting simulation and production verification,it is proved that the mold structure is reasonable and meet the requirements of actual production.First of all,Incorporation with the regular casting methods for aluminum alloy cylinder cover and its feature,the structure reform,more suitable for the application for LPCT,is proposed for certain engine cylinder cover.Based on the experiences of the casting mold design from home and abroad,the metal mold of the engine cylinder cover is designed,which is based on LPCT,principal fabrication and two cavities in a mold technology.The mold design process is investigated from the aspects of engine cylinder cover technology analysis,the relative low pressure casting equipment parameter checking,the overall design of the mold,the parting surface selection,the design of forming parts and mold body,the design of runner system and exhaust system.Second,Anycasting software,a finite element method based casting process,is used to simulate the filling and freezing process.The filling and freeing process of LPCT for engine cylinder cover are simulated and predicted the location of the defects,which provides to reform the design and a complete set of casting parameters.According to the simulation,defects of the mold are reformed to fabricate an applicable mold.Finally,the designed mold is invalided by the practical processing,and is a well performance mold which improved the productivity.The problems in casting process of aluminum alloy in low pressure casting including alloy melting,die installation and debugging,core making,core setting,pouring,picking up and knockout are mentioned.The ration of the mold design is invalidated by the check of surface quantitative,inner defects and metallurgical structure.The designed mold has reasonable structure,economic and practical advantages by the deeply studying,and which can provide experience for actual problems.The productivity and quality of the engine cylinder cover are improved in the current condition for manufacturing the engine cover,and provide valuable reference for the same style productions and castings.