Lightweight Design and Casting Process Optimization of the Aluminum Alloy Cover Plate Casting
In this paper,ANSYS simulation software was used to assist in lightweight design of the aluminum alloy cover plate casting,and AnyCasting simulation software was used to assist in optimization casting process.The ANSYS simulation results showed that the strength of the casting met the requirement of the hydraulic failure test before lightweight design.When the thickness of the casting wall was reduced by 3 mm,and there was a rupture risk of hydraulic failure test near the two small boss of the inner cavity.By changing the rounded corner R5 mm to R10 mm at the base of the boss,the casting rupture risk was eliminated.Further analysis showed that it was feasible to reduce the flange thickness by 5 mm,but it was not feasible to reduce the flange thickness by 10 mm.The AnyCasting simulation results showed that the filling and solidification processes were good and the casting had no defect before lightweight design.After lightweight design,the aluminum liquid temperature was relatively low during the filling process,multiple shrinkage and porosity defects appeared in the casting solidification process.The filling rate was increased from 880 Pa/s to 1 100 Pa/s,and the problems were eliminated.The trial production of the lightweight cover plate castings has been carried out and it has passed the validation of the hydraulic failure test.
万方数据
维普
