Die casting, referred to as die casting, is a kind of precision casting method in which liquid or semi liquid metal is filled into the die casting cavity under the action of high speed and high pressure, and the liquid metal is rapidly solidified into a casting under a certain pressure. Die casting has been widely used in automobile, aviation and other industries. At present, the die casting Market in developed countries has a high degree of maturity, and has a leading edge in equipment and technical level. Generally, die casting with high quality and high added value such as automobile, communication, aviation and so on is the main product. With the development of aluminum alloy die casting Market in China, the demand for aluminum alloy high pressure casting technology is very strong, and it also has great development potential. In the actual production, casting aluminum alloy has a higher difficulty, forming products will also be accompanied by defects. The use of computer-aided manufacturing technology can greatly reduce the defect rate of products and reduce the use of raw materials.
Die casting, referred to as die casting, is a kind of precision casting method in which liquid or semi liquid metal is filled into the die casting cavity under the action of high speed and high pressure, and the liquid metal is rapidly solidified into a casting under a certain pressure. Die casting has been widely used in automobile, aviation and other industries. At present, the die casting Market in developed countries has a high degree of maturity, and has a leading edge in equipment and technical level. Generally, die casting with high quality and high added value such as automobile, communication, aviation and so on is the main product. With the development of aluminum alloy die casting Market in China, the demand for aluminum alloy high pressure casting technology is very strong, and it also has great development potential. In the actual production, casting aluminum alloy has a higher difficulty, forming products will also be accompanied by defects. The use of computer-aided manufacturing technology can greatly reduce the defect rate of products and reduce the use of raw materials.
Many scholars at home and abroad have carried out experimental or numerical research on aluminum alloy die casting process. Zhang Junjie et al. Elaborated that by using numerical simulation technology, the product quality and material utilization rate of die casting parts have increased greatly, the cost has been reduced, and the design and manufacturing cycle of products have been reduced. According to the structural characteristics of the filter housing, Zhang Shuanglu et al. Designed the die-casting process scheme, used FLOW-3D software for numerical simulation, and predicted the location of defects by analyzing the distribution of air entrainment. According to the structural characteristics of the die casting, Li Bin simulated and analyzed the filling and solidification process of the casting by using the software of magma, and optimized the simulation results by orthogonal test. Li et al. Observed different types of pores in A356 high-pressure die-casting aluminum alloy by XRD and micro electronic scanning technology, and verified that cracks usually originated from shrinkage pores and gas shrinkage pores, rather than from gas pores through numerical simulation analysis of stress around the holes.
Based on the FLOW-3D software, the flow field, temperature field, oxide formation and other defects in the aluminum alloy die-casting filling process were designed. The process parameters in the results were analyzed and improved. The best process parameters were selected by orthogonal test method, which provided guidance for practical production and improved production efficiency.
1) Compared with other methods, the aluminum alloy steering wheel die casting is formed by side casting, which can basically meet the actual production requirements.
2) Through the orthogonal experiment simulation calculation of aluminum alloy steering wheel and the analysis of flow field, temperature field, surface defect and air volume under different process conditions, the optimized parameters a2b3c3 are the optimal horizontal combination: punch speed 3M · s-1, pouring temperature 920k, mold temperature 600k.