Taw qhia
Integrated tuag-casting thev naus laus zis muaj qhov zoo xws li kev tsim khoom siab thiab cov nqi tsim khoom tsawg. Tam sim no nyob rau hauv ib theem ntawm kev loj hlob sai, nws tuav lub peev xwm los tsim ntau yam khoom loj, ua kom lub cev yooj yim, thiab hloov pauv lub cev tsim khoom [1]. Kev sib koom ua ke tuag- nrum pem teb pem hauv ntej consolidates tshaj 70 thawj qhov chaw rau hauv ib feem, txo cov tsheb hnyav thiab txhim kho kev tsim khoom. Pwm, txheej txheem, tuag-casting tshuab, thiab cua sov- kho- cov ntaub ntawv pub dawb yog plaub lub thev naus laus zis ntawm kev sib xyaw tuag-casting [2-3]. Tuag-casting tshuab tshwj xeeb yog xa mus rau loj- cov cav tov nrog clamping quab yuam tshaj 60,000 kN [4]. Thaum tshav kub kub- kho- cov ntaub ntawv pub dawb feem ntau siv niaj hnub no yog siab - lub zog, siab -toughness cam khwb cia aluminium alloys [5], paub txog lawv lub zog tshwj xeeb, zoo heev castability, tus nqi nruab nrab, thiab cov xwm txheej yog cov khoom tseem ceeb rau tam sim no kev sib xyaw ua ke ntawm cov khoom siv tsheb tuag [6-7].
Hauv tsev loj aluminium tuag-castings ntsib qhov kev sib tw ntawm kev txo qis cov txiaj ntsig nrog nce kev sib koom ua ke nyuaj. Cov yam tseem ceeb cuam tshuam rau cov nqi tsim nyog muaj xws li:
1. Cov khoom tsis ruaj khov ntawm qhov tseem ceeb ntawm cov khoom thauj khoom tseem ceeb- cov ntsiab lus ntawm cov kabmob: Kev teeb tsa qhov chaw rau kev poob siab absorber yees, subframes, thiab C-cov ncej xav tau cov khoom siv tshuab siab. Cov cheeb tsam no feem ntau nyuaj rau kev sim ntsuas, yuav tsum tsis txhob muaj cov pores sab hauv tshaj cov qauv, thiab yuav tsum tsis txhob muaj qhov txias txias sab nraud. Tshwj xeeb tshaj yog, C- ncej installation nto ze ntawm lub log lub log yog qhov ua rau txias kaw.
2. Qhov ntev tsis ruaj tsis khov ntawm qhov tseem ceeb mating: Nyias - phab ntsa vaj huam sib luag sab vaj huam sib luag teeb tsa ntawm ntug casting yog qhov cuam tshuam rau sab hauv lossis sab nraud deformation, lossis txawm tias twisting (pem hauv ntej sab nraud, sab nraud). Qhov no cuam tshuam qhov kev ruaj ntseg tom qab mating nrog cov khoom sib koom ua ke thiab tuaj yeem ua rau ua ntej - tsim lub qhov tsis zoo, ua rau machining tsis ua haujlwm [8-15].
Txoj kev tshawb no ntiav simulation los kwv yees qhov tsis xws luag hauv kev sib koom ua ke tuag- nrum pem teb pem hauv ntej thiab ua kom zoo dua qhov rooj vag thiab cov dej ntws los txhim kho cov khoom siv sab hauv, txhawm rau muab cov ntaub ntawv siv rau kev tsim cov hlau loj zoo sib xws.
1 Cov yam ntxwv ntawm tus yam ntxwv thiab kev xav tau
Lub hauv paus hauv pem teb casting tsim cov hauv pem teb sab nraub qaum ntawm cov neeg caij tsheb, kev sib koom ua ke xws li sab laug / sab xis rear wheelhouses, rear longitudinal beams, crossbeams, pem teb kev twb kev txuas daim hlau, thiab sab hauv beam reinforcements. Lub casting muaj tag nrho qhov ntev ntawm 1,630 hli × 1,624 hli × 666 hli, qhov hnyav ntawm 63 kg, nruab nrab phab ntsa thickness ntawm 3 hli, thiab ib cheeb tsam ntawm 23,000 cm². Vim nws qhov loj me, cov phab ntsa nyias, thiab qhov xav tau ntawm qhov chaw tseem ceeb, lub sij hawm mus sij hawm ntev, thiab kev pheej hmoo cuam tshuam nrog kev kho cua sov, kev kho cua sov -kev kho- dawb aluminium alloy yog raug yuam.
SPR (Tus Kheej-Piercing Riveting) txheej txheem yog tsim rau kev sib koom ua ke sib txawv ntawm cov hlau tsis sib xws-cov ntaub ntawv txhuas [8]. Yog li ntawd, lub casting pem hauv ntej thiab nram qab kawg txuas mus rau pem hauv ntej pem teb thiab rear pem teb sib dhos, raws li, ntawm SPR. Lub log sab laug thiab sab xis tuaj yeem txuas rau sab panels ntawm SPR. Thaum cov plaub ntug no tsis yog thawj qhov chaw thauj khoom-cov kabmob thaj tsam ntawm pem teb tom qab, lawv xav tau kev sib khi thiab kev sib raug zoo, sib haum rau cov kev xav tau rau kev sib tw thiab lub zog siab - toughness ntawm cov khoom.
Kev Xav Tau Zoo: Tsis muaj qhov tsis xws luag xws li txias kaw, tawg, thiab chips.
Cov Khoom Siv Ua Tau Zoo (Pre- ci):
SPR Qhov Chaw (Lub Cev Sampling): Tensile Strength Ntau dua los yog sib npaug rau 215 MPa, Yield Strength Ntau dua lossis sib npaug rau 115 MPa, Elongation Ntau dua lossis sib npaug li 12%, Khoov Lub kaum sab xis siab dua lossis sib npaug li 20 degree.
Sab Nrauv Ib Nrab Ntawm Lub log (qis me ntsis): Tensile Strength Ntau dua los yog sib npaug rau 215 MPa, Lub zog muaj zog ntau dua lossis sib npaug rau 110 MPa, Elongation Ntau dua lossis sib npaug li 6%, Khoov Lub kaum sab xis siab dua lossis sib npaug li 20 degree.
Lwm thaj chaw: Elongation yuav tsum tau ntawm 6% thiab 12%.
Kev txiav txim siab qhov tsis sib xws ntawm cov khoom siv kho tshuab hauv tuag- cov qauv cam khwb cia, ua kom tiav cov khoom siv kho tshuab nyob txhua qhov chaw hauv cheeb tsam yog qhov nyuaj. Yog li ntawd, kev ntsuam xyuas lub rooj ntev zaum yuav tsum tau ua kom paub tseeb qhov tseem ceeb ntawm cov khoom thauj - bearing kev ua tau zoo ntawm cov shock absorber towers thiab longitudinal beams [9]. Kev ntsuam xyuas lub rooj zaum feem ntau muaj xws li durability thiab crush tests:
Durability thiab Z-kev taw qhia Crush Tests: Simulate rear shock absorber loading. Durability xeem txhais tau tias load yog 11.5 kN. Nyob rau hauv Z-kev taw qhia crush, thawj-theem loading ntawm 38 kN yuav tsum loading point deformation Tsawg dua los yog sib npaug rau 3 hli; thib ob-theem loading ntawm 74 kN yuav tsum tsis txhob tawg ntawm qhov chaw thau khoom.
X-kev taw qhia Crush Test: Simulates longitudinal beam loading. Nyob rau hauv unilateral loading quab yuam Ntau tshaj los yog sib npaug zos rau 206 kN, tsis muaj cracking thiab deformation Tsawg tshaj los yog sib npaug zos rau 3 hli yuav tsum tshwm sim ntawm lub loading point.
2 Tuag- Casting Process Design
2.1 Gating System Design
Hauv pem teb tsim kho muaj lub hau npog phaj txuas qhov rais ntawm nws sab pem hauv ntej kawg. Txawm li cas los xij, nws qhov sib piv siab (3.14) thiab qhov chaw ntug ua rau qhov chaw nruab nrab tsis haum. Ib qho -sab qhov rooj mus kom ze, raug rau cov pa tuag-castings, raug saws. Raws li Magma flow tsom xam, peb tus qauv khiav (S1, S2, S3) tau ua kom zoo dua:
S1 thiab S2 tsim siv 70,000 kN tuag-casting tshuab.
S3 tsim siv 120,000 kN tuag- tshuab casting, koom nrog kev txhim kho me me rau lub cev casting, thiab nce lub plunger txoj kab uas hla, tus naj npawb ntawm ingates, thiab ingate cheeb tsam.
2.2 Filling thiab Solidification Simulation Analysis
Magma software simulated pem hauv ntej tuag- txheej txheem casting. Cov khoom siv pwm yog H13 cov cuab yeej hlau; Cov khoom siv casting yog C611 siab -lub zog, siab -toughness aluminium alloy [1]. Cov txheej txheem: Melt kub 680 degree, Plunger kub 200 degree, txhaj tshuaj kub 250 degree, Pwm kub 180 degree. Txhaj tshuaj tsis sib txawv ntawm ib lub tswv yim.
Scheme S1 Analysis Results:
Thaum kawg - ntawm -sau, lub log tsev ntug txoj hauj lwm muaj qhov kub siab tshaj plaws (~618.6 degree) thiab solidified ua ntej (cov khoom seem ~ 1%). Qhov tseeb casting yuav tsum tau yaj ntau dua thiab tsom xyuas cov pwm saum npoo kub hauv cheeb tsam no. Vim cov pwm kub hloov pauv, qhov kev pheej hmoo kaw txias muaj nyob nruab nrab ntawm -section wheelhouse edge.
Thaum yaj mus txog rau hauv qab kab noj hniav ib nrab, qhov txwv qhov chaw ntws ua rau txhaws nrawm txog 60 m / s. Ob lub kwj deg sib sau ua ke ntawm qhov nruab nrab ntawm qhov kawg crossbeam. Kev kub ceev ua rau yaj swirling, tsim kom muaj kev pheej hmoo ntawm txias kaw thiab tawg, txo cov khoom siv kho tshuab.
Ib kauj ruam tseem ceeb sib txawv thiab cov phab ntsa tuab nyob ze ntawm qhov nkag ntawm lub nraub qaum sab nraub qaum ua rau cov hnab ntim huab cua loj ntawm ob sab. Machined qhov nyob rau hauv cheeb tsam no ua porosity defects detrimental rau yield.
Tom qab yaj nkag mus rau hauv lub sill beam, casting siab tsis tu ncua mus rau 30 MPa. Raws li lub cev casting qhov projected cheeb tsam (18,136 cm²), qhov no yuav tsum tau ib tug clamping quab yuam ntawm 69,000 kN. Xav txog qhov kev nyab xeeb ntawm 1.2 thiab suav nrog lub rooj vag system (kwv yees thaj tsam ~ 25,000 cm²), qhov xav tau clamping quab yuam mus txog 90,000 kN, tshaj 70,000 kN tshuab lub peev xwm.
Scheme S2 Analysis Results:
Ntxiv ib tug khiav ncaj nraim ntawm lub wheelhouse txo lub log lub sij hawm sau rau 51 ms (vs . 59 ms rau S1). Tag nrho cov sij hawm sau yog 86 ms.
Turbulence nyob rau hauv ob lub wheelhouses tau ntau pronounced. Cov ntsiab lus roj tau siab tshaj plaws ntawm qhov sib xyaw ua ke ntawm qhov sib xyaw ua ke ntawm qhov hla ntawm qhov kawg - ntawm - sau, tsim kom muaj kev pheej hmoo siab rau porosity, tawg, thiab shrinkage defects [7].
Qhov teeb meem dej txias hauv cheeb tsam wheelhouse tsis tau daws tau zoo.
Scheme S3 Analysis Results:
Optimizing tus khiav raws li cov txheej txheem dhau los, cov dej ntws tau ntxiv rau ntawm lub log tsev ntug qhov chaw thiab qhov kawg crossbeam center. Ingate cheeb tsam tau nce ntxiv (yuav tsum tau txhaj tshuaj ntau zog kom ceev ceev). Lub tshuab clamping quab yuam tau hloov kho mus rau 120,000 kN.
Wheelhouse ntug kub yog qis dua S1 / S2 tab sis nyob ze ntawm cov kua dej kub. Melt mus txog ingates ntawm 305 ms (lub sij hawm pib los ntawm biscuit sau), nrog ib tug max ceev ntawm 60 m / s. Cov kab noj hniav puv nkaus ntawm 390 ms, noj 85 ms. Casting siab yog 40 MPa.
Raws li S3 gating system projected cheeb tsam (25,813 cm²), qhov siab tshaj plaws casting siab lub 120,000 kN tshuab tuaj yeem muab tau yog 46.5 MPa, ua tau raws li qhov yuav tsum tau ua.
Cov dej ntws hla ntxiv ntawm ib sab ntawm lub wheelhouse txhim kho huab cua nkag piv rau S2. Qhov sib thooj rau lub ingate kuj txo porosity txaus ntshai.
Lub tswv yim S3 tau xaiv rau kev tsim pwm.
3 Kev sim thiab cov txiaj ntsig
3.1 Tuag-Casting Parameters thiab Test Methods
Kev tsim khoom siv Lijin 120,000 kN tuag-casting tshuab. Alloy yog C611 tshav kub- kho- cov khoom siv dawb (cov tshuaj muaj pes tsawg leeg raws li cov lus qhia tshwj xeeb). Piv nrog rau cov khoom siv AlSi10MnMg ib txwm muaj, cov khoom siv hluav taws xob kub- kho- dawb alloys muaj kev zoo dua li - nrum toughness, zoo rau riveting. Melt kub yog 680 degree. Lub tshuab nqus tsev dynamic thiab ruaj khov yog 10 kPa.
Txheej txheem ntws: Txau → Tshuab- tawm → Pwm kaw → Pouring → Nqus evacuation → Txhaj → Hauv zos Squeeze → Direct Cooling/Spot Cooling → Mould Opening → Robot Extraction → Integrity Check → Water Quenching → Trimming & Straightening → Robot Deburring → Pom & Dimensional Check → Hloov mus rau txheej txheem tom ntej.
Kev soj ntsuam zoo sab hauv siv Maice FSC hnyav-lub luag haujlwm 9-axis X-ray kuaj tshuab. Tensile specimens tau xub txiav los ntawm lub cev casting raws li me me (80-100 mm ntev, 15-30 mm dav), ces machined rau hauv cov qauv tensile specimens nrog ib tug 25 hli gauge ntev.
3.2 Internal Quality Inspection
X-Ray soj ntsuam cov txiaj ntsig tau pom tias tsis muaj qhov cuam tshuam loj heev ntawm qhov chaw nkag, sab nraub qaum, lossis sab lub log ntawm lub hauv ntej hauv pem teb casting. Sab hauv zoo tau raws li ASTM E505 Qib 2 tus qauv. Vim yog cov phab ntsa tuab, machining qhov tus thawj coj tau yoog rau qhov porosity, yuav tsum tau kuaj xyuas ntxiv rau qhov pom qhov pores thiab ua raws li cov qauv zoo li. Load retention tests for threaded inserts or self-tapping screws tau ua los ntawm CMT5305 tensile kuaj tshuab.
3.3 Tensile Mechanical Properties los ntawm Lub Cev Sampling
Cov cuab yeej siv tshuab tau sim ntawm 39 qhov chaw ntawm lub cev casting. Cov ntsiab lus piv txwv tau muab faib ua symmetrically (L: Sab laug lub cev, R: sab xis lub cev), npog thaj chaw tseem ceeb:
Txoj hauj lwm 1-10: Wheelhouse ntug (sab riveting ntug).
Txoj hauj lwm 11-20: Wheelhouse nruab nrab seem.
Txoj hauj lwm 21-23: Ingate cheeb tsam (rov qab pem teb sib dhos riveting ntug).
Txoj hauj lwm 31-34: Pem hauv ntej npog phaj txuas ntug.
Txoj hauj lwm 35-37: pem hauv ntej pem hauv ntej riveting ntug ntawm qhov kawg-ntawm-sau.
Cov txiaj ntsig:
Tensile zog (TS) thiab yield zog (YS) kuj ruaj khov nyob rau hauv qhov chaw. Qhov nruab nrab TS yog 237 MPa; Qhov nruab nrab YS yog 118.9 MPa.
Elongation sib txawv ntawm qhov chaw, qhov nruab nrab tsuas yog 6.5%, nrog qee cov ntsiab lus hauv qab 6%. Qhov nruab nrab elongation tus nqi yog cuam tshuam los ntawm qhov chaw kuaj thiab qhov ntau thiab tsuas yog siv raws li kev siv [9]. Rau kev sib piv, lwm pem teb pem hauv ntej siv tib yam khoom tiav qhov nruab nrab elongation ntawm 9%.
Raws li tus neeg siv khoom xav tau kev txhim kho thawj zaug, lub cev lub cev (tshwj xeeb tshaj yog elongation ntawm qee qhov chaw) tsis tuaj yeem ua tiav. Yog li ntawd, lub cev sampling tshwm sim ib leeg tsis tuaj yeem yog tus qauv tsim nyog rau cov khoom tsim nyog. Qhov kev ua tau zoo tag nrho yuav tsum raug txiav txim raws li kev ntsuas lub rooj ntev zaum thiab tag nrho cov txiaj ntsig ntawm lub tsheb validation.
4 Kev xaus
(1) Magma software tau siv los tsim thiab txhim kho lub rooj vag rau C611 aluminium alloy rear pem teb casting. Kev simulation qhia tau hais tias cov phab ntsa thickness variations tseem ceeb nyob rau hauv cov kauj ruam cheeb tsam, ua ke nrog tsawg melting kub uas ntws los ntawm cov cheeb tsam no, tsim kev txaus ntshai rau huab cua entrapment, txias shuts, thiab tawg. Kev soj ntsuam ntawm kev sau siab nyob rau hauv qhov kawg crossbeam cheeb tsam qhia tau hais tias ib tug tuag-casting tshuab nrog ib tug clamping quab yuam tshaj 90,000 kN yog tsim nyog rau ua tiav txoj kev ntawm lub rear pem teb.
(2) Xaiv lub 120,000 kN tuag-casting tshuab rau ntau lawm, ua ke nrog simulation-raws li optimization, zoo tshem tawm porosity thiab shrinkage porosity defects. Txawm li cas los xij, cov kab nrib pleb nquag tshwm sim hauv thaj chaw hloov chaw thiab thaj chaw uas muaj cov phab ntsa tuab ntawm qhov sib txawv cuam tshuam rau cov khoom siv kho tshuab. Qhov nruab nrab lub zog, lub zog tensile, thiab elongation los ntawm cov qauv txiav los ntawm C611 rear pem teb casting lub cev yog 118.9 MPa, 237 MPa, thiab 6.5% feem, qhov tseem ceeb ua tau raws li lub hom phiaj tseem ceeb (TS Ntau dua lossis sib npaug rau 215 MPa, YS Ntau dua lossis sib npaug rau 115 MPa ntau dua).
(3) Muab piv rau cov txheej txheem tsim ib txwm muaj xws li riveting thiab stamping, cov khoom sib xyaw ua ke- cam khwb cia hauv pem teb tau ua tiav qhov hnyav tshaj li 10%. Yav tom ntej kev saws me nyuam ntawm 200,000 kN tuag-casting tshuab tuav cov lus cog tseg rau kev ua tiav luv- voj voog, qis- nqi, thiab siab - lub zog / siab-toughness manufacturing ntawm integrated automotive lub cev castings.