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根据实际生产中倾斜铸造工艺特点,采用有限元软件ProCAST对制动器卡钳体充型和凝固过程进行数值模拟。通过对充型过程的结果分析,研究了铝液流场和温度场的分布特点;通过对凝固过程的结果分析,研究了铝液固相率的变化规律,并预测了缺陷位置。结果表明,在充型过程中铝液流动平稳,无冷隔浇不足等缺陷;在凝固过程中存在缩孔、缩松缺陷,主要集中在臂端、底部厚大部位及中心通孔附近。最后提出工艺优化方案并进行模拟,改善了卡钳体缩孔缩松的分布情况,并运用到实际生产进行验证,提高了铸件成品率。
According to the characteristics of tilting casting process in actual production, finite element software ProCAST was used to simulate the body shape and solidification of brake calipers. Through the analysis of the results of filling process, the distribution characteristics of flow field and temperature field in liquid aluminum were studied. The change rule of liquid solid fraction was studied by analyzing the result of solidification process, and the position of defect was predicted. The results show that during the filling process, the flow of molten aluminum is smooth and there is no defects such as cold pouring. In the process of solidification, there are shrinkage and shrinkage defects, which are mainly concentrated at the arm end, the thick bottom and the central through hole. Finally, the process optimization program is proposed and simulated to improve the caliper shrinkage shrinkage distribution, and used to verify the actual production, improve the casting yield.