I. Introduction
- The cylinder block is a crucial and complex part in automotive engines, reflecting the overall technical, managerial, and personnel capabilities of a foundry.
- With the development of computer technology, numerical simulation has become an essential tool in the casting process, especially for simulating the challenging casting of engine cylinder blocks.
- This article uses the MAGMA software to simulate the casting filling process of a specific engine cylinder block, analyzing temperature field, gas pressure, and air entrapment distributions under different pouring times, and validates the results in actual production.
II. Simulation Preparation
- Assembly and Export: Assemble the casting, gating system, riser, sand core, and mold in Pro/E and export them in.sn format using the same coordinate system.
III. Simulation Results and Analysis
1. Temperature Field Distribution
- The simulation shows how the temperature changes during the filling process of the cylinder block in sand casting, providing insights into the solidification behavior. (Figure 1: Temperature Field Distribution at Different Pouring Times)
2. Gas Pressure Distribution
- Analyzes the gas pressure distribution within the mold cavity during casting, which is crucial for understanding the potential formation of gas holes. (Figure 2: Gas Pressure Distribution during Casting)
3. Air Entrapment Distribution
- Reveals the areas where air is likely to be trapped during the casting process, affecting the quality of the cylinder block. (Figure 3: Air Entrapment Distribution in the Casting)
4. Prediction of Gas Hole Defects
- Predicts the distribution and severity of gas holes in the cylinder block under two different pouring times, and the results are verified in actual production. (Table 1: Comparison of Gas Hole Defects at Different Pouring Times)
| Pouring Time | Gas Hole Distribution | Severity |
|---|---|---|
| Time 1 | [Describe distribution] | [Describe severity] |
| Time 2 | [Describe distribution] | [Describe severity] |
IV. Conclusion
- The application of MAGMA in simulating the sand casting process of the engine cylinder block effectively predicts gas hole defects, providing valuable references for analyzing defect causes and improving the casting process in actual production. It also establishes a reliable simulation model for guiding future production.