目的 针对某企业研制的高性能改性灰铸铁制动鼓铸件充型凝固行为,建立改性灰铸铁制动鼓铸造成型有限元模型,模拟其充型及凝固过程,达到预测和控制铸造缺陷、优化工艺参数和提高产品质量的目标。方法 通过JMatPro软件计算改性灰铸铁材料属性并修正材料模型,基于Procast软件建立有限元模型,模拟其成型过程,分析改性灰铸铁铸造成型工艺特点和缩松分布特点;以浇注系统结构、浇注温度和浇注时间为设计变量,以缩松孔隙率为优化目标,优化改性灰铸铁制动鼓的铸造工艺,并进行试验验证。结果 改性后灰铸铁的固相含量、密度发生了显著改变,固相线和液相线下降至1 072 ℃和1 190 ℃。在铸造过程中,熔体按自下而上的顺序充填,无飞溅及支流汇合,充型过程良好;在凝固过程中,在工件加强筋靠近内浇口处出现孤立液相区,导致出现缩松缺陷,实验结果与模拟结果一致;改进优化浇注系统结构和工艺参数后的改性灰铸铁制动鼓的缩松孔隙率为0.86%,成型质量较好,最佳浇注温度为1 425 ℃,最佳浇注时间为30 s。结论 将材料属性计算、有限元模拟和工艺实验相结合,能够有效预测和控制铸件缺陷,指导生产过程中的工艺改进,提高产品质量。
Abstract
The work aims to study the filling and solidification behavior of high-performance modified gray cast iron brake drums developed by a casting company, establish a finite element model for the casting of modified gray cast iron brake drums, simulate their filling and solidification processes, and achieve the goals of predicting and controlling casting defects, optimizing process parameters and improving product quality. The material properties of the modified gray cast iron were calculated using JMatPro software, and the material model was modified. Based on Procast software, a finite element model was established to analyze the forming process characteristics and shrinkage porosity distribution of modified gray cast iron. Meanwhile, the gating system structure, gating temperature, and gating time were taken as design variables, with shrinkage porosity as the optimization target, to optimize the casting process of the modified gray cast iron brake drum, followed by experimental validation. The results showed that the solid-phase content and density of the modified gray cast iron changed significantly after modification, with the solidus and liquidus temperature decreasing to 1 072 ℃ and 1 190 ℃, respectively. During the casting process, the melt filled the mold from bottom to top in a sequential manner, with no splashing or branch flow convergence, resulting in a good filling process. However, during solidification, isolated liquid-phase regions appeared near the inner gating on the ribs of the workpiece, leading to shrinkage defects. Experimental results were consistent with simulation results. After optimizing the gating system structure and process parameters, the shrinkage porosity of the modified gray cast iron brake drum was reduced to 0.86%, with good molding quality. The optimal gating temperature was found to be 1 425 ℃, and the best gating time was 30 s. Through the integration of material property computations, finite element modeling, and experimental validation, casting defects can be accurately predicted, thereby facilitating the optimization of production processes and contributing to the enhancement of product quality.
关键词
改性灰铸铁 /
制动鼓 /
数值模拟 /
工艺优化 /
缩松
Key words
modified gray cast iron /
brake drum /
numerical simulation /
process optimization /
shrinkage porosity
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基金
中央引导地方科技发展专项（2023EGA026）
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