一种基于3D打印快速制造铝合金传动箱箱体的方法

传动箱箱体铸件,需要进行压力渗漏检查,尺寸和内部质量很难同时保证,短期快速制造难度很大。对传动箱箱体结构和质量要求进行分析,选择合适的快速制造工艺路线。通过铸件结构优化设计、铸造工艺设计、铸造工艺模拟优化、3D打印蜡模、石膏型电磁真空增压铸造、质量检验等主要工序,实现传动箱箱体快速制造。整个生产周期缩短到7~15个工作日,内部质量优于2级,尺寸精密CT5~CT7,光洁度优于Ra5.0,达到传动箱箱体质量要求。3D打印蜡模和石膏型真空增压铸造融合可以实现无模快速制造传动箱箱体,它通过真空环境浇注、加压补缩过程凝固、内置冷铁等工艺手段,解决了传动箱箱体质量不稳定、制造周期长、加工量大、补焊、尺寸不稳定、内部缺陷多、反修次数多等现有制造问题。

A fast manufacturing method of aluminum alloy transmission box body based on 3D printing

The transmission box castings require pressure leakage inspection.It is difficult to guarantee both size and internal quality at the same time,and it is difficult to manufacture them quickly in the short term.The structure and quality requirements of the transmission box have been analyzed while the appropriate rapid manufacturing process route has been selected.Through the main processes of optimized design of casting structure design,casting process design,casting process simulation optimization,3D printing wax pattern,gypsum type electromagnetic vacuum booster casting,quality inspection,etc.,the fast manufacturing of transmission box has been realized.The entire production cycle has been shortened to 7~15 working days while the internal quality is better than 2 grades,the size precision is CT5~CT7,and the finish is better than Ra5.0,which meets the quality requirements of the transmission box.The combination of 3D printed wax mold and gypsum-type vacuum pressurized casting can realize the rapid manufacturing of transmission box without mold.It solves existing manufacturing problems of transmission box such as instability,long manufacturing cycle,large processing volume,repair welding,unstable dimensions,many internal defects,and many times of rework through the vacuum environment casting process,solidification during pressurization and filling,and built-in cold iron.