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Accurate Simulation of Complex Temperature Field in Counter-Pressure Casting Process Using A356 Aluminum Alloy
International Journal of Metalcasting ( IF 2.6 ) Pub Date : 2020-04-03 , DOI: 10.1007/s40962-020-00456-9
Yuncan Tian , Dongye Yang , Mengqi Jiang , Bo He

Automobile steering knuckle is an important part of the steering system, which is subjected to significant impacts and loads during its operation. Generally, cast aluminum steering knuckles are usually produced using some type of enhanced low-pressure casting process, like counter-pressure casting. Compared with aluminum forging and sand cast ductile iron, it can improve the production speed and achieve the adequate casting quality. In this study, various methodologies such as dynamic thermomechanical analysis, differential scanning calorimetry, and the laser flash method were employed to study the thermophysical properties of AlSi7Mg0.3. Further, the physical model of a counter-pressure casting system with an aluminum interior was established based on the combination of the tested and the theoretical properties of aluminum; this was achieved with the consideration of the presence of other factors including rapid solidification. The temperature field of the system was computed and verified by thermocouples at six different points during the tooling and the shrinkage simulation. It was observed that the plot shape of the computed temperatures and that of the simulated ones correlated; further, the difference between the peaks and the valleys was controlled to be 3% on an average, with the maximum variation of 7% at only one point. Moreover, all the predicted shrinkages were verified by the casting. This study provides a solid foundation for facilitating the simulation of the morphologies of the microstructure.



中文翻译:

A356铝合金在反压铸造过程中复杂温度场的精确模拟

汽车转向节是转向系统的重要组成部分,在操作过程中会受到很大的冲击和载荷。通常,铸铝转向节通常使用某种类型的增强型低压铸造工艺来生产,例如反压铸造。与铝锻造和砂铸球墨铸铁相比,可以提高生产速度,达到足够的铸造质量。在这项研究中,采用各种方法,例如动态热机械分析,差示扫描量热法和激光闪光法,研究AlSi 7 Mg 0.3的热物理性质。。此外,根据铝的测试特性和理论特性,建立了具有铝内部结构的反压铸造系统的物理模型。这是通过考虑其他因素(包括快速凝固)的实现来实现的。在加工和收缩模拟过程中,通过六个不同点的热电偶计算并验证了系统的温度场。可以看出,计算出的温度和模拟温度的曲线形状相互关联。此外,峰谷之间的差异平均控制为3%,仅在一个点上最大变化为7%。此外,所有预测的收缩率都通过铸造进行了验证。

更新日期:2020-04-18
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