基于Magma数值模拟的汽油机活塞铸造过程优化

利用Magma软件对某汽油机铝合金活塞铸造过程进行了数值模拟,根据出现的铸造缺陷类型及位置对铸造模具进行了优化。结果表明,在顶模前端增加铝液存储槽后,避免了前端容易被氧化的铝液在顶面停留,从而减少铝液填充到顶面时因模具排气不畅而形成的气孔缺陷,并运用染色及CT扫描检测技术验证了模拟结果与实际生产的一致性。通过小批量生产验证,活塞顶面铸造缺陷由原来的50%降低至5%以内,有效地解决了活塞顶面铸造缺陷,提高了产品品质。

Optimization of Casting Process for Gasoline Engine Piston Based on Numerical Simulation

The casting process of aluminum alloy piston for a gasoline engine was simulated by Magma software.The mould was optimized according to the types and location of casting defects.The results reveal that the liquid aluminum storage tank on the front end of top die can avoid the liquid aluminum that is easily oxidized in front remaining on the top,so as to reduce the air hole defects caused by poor exhausting of the mold when the aluminum liquid is filled to the top surface.The consistency between the simulated results and the actual production has been verified by dyeing and CT scanning technology.Through small batch production verification,piston top casting defects has been reduced from 50%to less than 5%,solving effectively the casting defects on the top surface and improving the product quality.