吴复涛 王娟 李鑫 谭建波

摘 要：为解决低压铸造过程中容易产生气孔、夹渣、缩松等问题，研究了铸造工艺参数对低压铸造AlSi9Mg变速箱下壳充型及凝固过程的影响。依据Pro/Engineer软件绘制2种不同浇注系统的变速箱下壳三维实体模型，利用ProCAST软件进行数值模拟，探讨浇注温度、铸型温度及充型压力等对AlSi9Mg变速箱下壳低压铸造时金属液充型及凝固过程的影响，以标准化正交表对实验结果进行有效分析。结果表明，较合理的工艺参数为浇注温度700 ℃、铸型温度350 ℃、充型压力45 kPa，在此工艺参数下铝合金变速箱下壳铸件缩孔、缩松缺陷体积由原来的1.537 cm3降为1.425 cm3。对AlSi9Mg变速箱下壳低压铸造工艺进行模拟研究，可为变速箱下壳低压铸造工艺的优化提供参考依据，具有实际应用价值。

关键词：铸造工艺与设备;低压铸造;ProCAST;数值模拟;变速箱下壳;工艺优化

中图分类号：TG249.2;TP311 文献标识码：A

doi：10.7535/hbkd.2021yx03013

Simulation and optimization of low pressure casting process for AlSi9Mg gearbox shell

WU Futao1，2， WANG Juan3， LI Xin3， TAN Jianbo1，2

（1.School of Material Science and Engineering，Hebei University of Science and Technology，Shijiazhuang，Hebei 050018，China;

2.Hebei Key Laboratory of Material Near-net Forming Technology，Shijiazhuang，Hebei 050018，China;

3.Tangshan Caofeidian Jidong Equipment Mechanical Foundry Company Limited，Tangshan，Hebei 063200，China）

Abstract：In order to solve the problems of porosity，slag inclusion，shrinkage porosity，etc.，the influence of low pressure casting process parameters on filling and solidification of the AlSi9Mg gearbox shell was studied.Two different gating systems of the three-dimensional solid model were drawn with Pro/Engineer software，and the influence of pouring temperature，mold temperature and filling pressure on the alloy filling and solidification process during low pressure casting of the AlSi9Mg gearbox shell were studied through the method of numerical simulation using ProCAST software.Based on the experimental results，effective analysis was conducted with orthogonal test table.The result shows that the reasonable process parameters are as follows：Pouring temperature 700 ℃，mold temperature 350 ℃ and filling pressure 45 kPa，and under these process parameters，the defect volume of shrinkage pore of the casting is reduced from 1.537 cm3 to 1.425 cm3.The research on simulation and optimization of low-pressure casting process of AlSi9Mg gearbox lower shell can provide reference for optimization of low-pressure casting process of gearbox lower shell，and has practical application value.

Keywords：

casting process and equipment;low pressure casting;ProCAST;numerical simulation;gearbox shell;process optimization

汽車工业正向轻合金铸件方向加速发展，这也是减轻汽车质量效果最好的办法[1-5]。AlSi9Mg合金具有强度高、密度低、热膨胀系数小、热稳定性高等优点，广泛用于汽车、航空、航天、机械、热能工程等领域[6-11]。变速箱是汽车传动系统的重要保护装置，承担内部零件安装、润滑及散热等多项功能，属于形状复杂的薄壁大尺寸铸件[12-15]。人们在变速箱壳体模拟及工艺方面进行了一些探索，尤其是在利用数值模拟分析不同工艺参数对铸件缺陷的影响方面[16-20]。AlSi9Mg变速箱下壳为箱体类铸件，质量要求高，但在低压铸造过程中容易产生气孔、夹渣、缩松等缺陷。……