Optimization of Squeeze Casting Process for Aluminum Alloy Engine Support with Large Wall Thickness Difference

Li Jindong; Ji Zesheng; He Weiming; Jiang Bo; Hu Maoliang; Song Weisheng; Wang Yunlong; Zhang Yongbing

doi:10.15980/j.tzzz.2022.11.027

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Optimization of Squeeze Casting Process for Aluminum Alloy Engine Support with Large Wall Thickness Difference
Vol. 42, Issue 11, Pages: 1444-1449(2022)
Published： 2022 ，
DOI： 10.15980/j.tzzz.2022.11.027

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Li Jindong, Ji Zesheng, He Weiming, et al. Optimization of Squeeze Casting Process for Aluminum Alloy Engine Support with Large Wall Thickness Difference. [J]. Special Casting & Nonferrous Alloys 42(11):1444-1449(2022)
DOI：

Li Jindong, Ji Zesheng, He Weiming, et al. Optimization of Squeeze Casting Process for Aluminum Alloy Engine Support with Large Wall Thickness Difference. [J]. Special Casting & Nonferrous Alloys 42(11):1444-1449(2022) DOI： 10.15980/j.tzzz.2022.11.027.

摘要

针对大壁厚差支架铸造过程中易出现缩孔、缩松缺陷的问题，运用ProCAST软件模拟了间接挤压铸造工艺的充型和凝固过程，预测缺陷的位置并优化了方案。结果表明，采用大尺寸内浇口、低速充型可以消除成形过程的卷气、夹渣和通孔处的缩孔、缩松缺陷。挤压压力为75 MPa时，缺陷集中在凸台部位，且无法在冲头压力作用下消除。设计局部挤压方案，在挤压压力为75 MPa、浇注温度为700℃、模具温度为200℃下，模拟得出最佳挤压销激活时间为1.1 s

取出时间为9.5 s。试验验证表明，经过局部挤压，消除了凸台部位的缺陷。

Abstract

In order to solve the problem of shrinkage porosity defects in the casting process of bracket with large wall thickness difference

the filling and solidification process of indirect squeeze casting process were simulated by the ProCAST software

and the positions of defects were predicted and the casting process was optimized.The results show that the defects of air entrainment

slag inclusion and shrinkage at the through-hole can be eliminated by using large-size gate and low pouring speed. However

the defects are concentrated in the boss with the extrusion pressure of 75 MPa

which can not be eliminated by feed system. Localized squeezing process was designed

and the optimal activation time of squeeze pin was simulated to be 1.1 s and removal time was 9.5 s at 75 MPa

a pouring temperature of 700 ℃ and a die temperature of 200 ℃. The experiment results indicate that the defects of the boss are eliminated after local extrusion.