利用数值模拟解决灰铸铁制动盘缩松的问题

运用数值模拟软件对DISA线生产灰铸铁制动盘3种不同工艺方案的铸造过程进行模拟。通过对充型温度场和热节点分布进行对比分析,发现仅仅加冒口或者局部设置冷铁不能够彻底解决缩松问题,需要同时加冒口和局部设置冷铁,局部冷铁的厚度要按照经验公式L/H3来决定,这样可以彻底解决制动盘的缩松问题。利用同时加冒口和冷铁配合的方法生产一批铸件后,经X射线探伤机检测的11件铸件,全部未发现缩松缺陷存在,表明对缩松缺陷的预测是准确的。

Using Numerical Simulation to Solve Shrinkage Porosity Problem of Gray Iron Brake Disc

The casting process of three different casting methods for gray iron brake disc production on DISA molding line was simulated. By comparing the mold-filling temperature field and distribution of hot spots,it was found that it’s impossible to solve shrinkage porosity problem only by setting riser or only by locally setting densener. In order to thoroughly solve the shrinkage porosity problem,it’s necessary simultaneously to set riser and local densener,and the thickness of the local densener must be determined according to the experiential formula L/H〈3. After a batch of castings was produced by using riser plus densener method,11 pieces castings were detected with X-ray and no shrinkage porosity defect was found with all castings that showed the porosity forecast was reliable.