铸件缺陷机理分析及凝固温度场工艺优化

针对某型号发动机Y进口管疏松缺陷问题,基于ProCAST铸造仿真模拟软件,阐述了缺陷产生机理,建立了合金充型凝固可视化模型,得出冷铁设计不合理是缺陷产生的根本原因。通过调整冷铁结构及尺寸,协调各部分冷却速度,优化凝固温度场分布,从而建立了自下而上的凝固顺序,保证铸液补缩通道的通畅,原缺陷部位合金液得到补充,消除疏松缺陷。小批量生产验证结果表明:铸件X光透视检查未见疏松缺陷,铸件合格率由60%提高到92.8%,生产周期由4个月缩短至1个月。

Analysis of casting defect mechanism and optimization of solidification temperature field

Aiming at the loosening defect of Y inlet pipe of a certain type of engine,its produce mechanism was expounded,and the visual model of alloy filling and solidification was established based on procast casting simulation software,as result it is found that unreasonable design of chilled iron is the main reson which causes such problem.By adjusting the structure and size of the chilled iron,coordinating the cooling rate of each part,optimizing the distribution of the solidification temperature field,a bottom-up solidification sequence was established to ensure the smoothness of the molten liquid feeding channel,and the alloy liquid of the original defect was replenished to eliminate looseness defect.The results of small batch production verification show that there was no loose defect in the X-ray inspection of the casting,the casting qualification was increased from 60%to 92.8%,and the manufacturing cycle was shortened form four months to one month.