The Numerical Simulation And Process Parameter Optimization In Aluminum Alloy Wheel Hub Die Casting

Aluminum alloy wheel hub, which has advantages such as less density, higher strength to mass ratio, corrosion resistance and better processability etc, is widely used in automobile industry. For reducing the die casting defects in maximum and improving the density and strength, the aluminum alloy wheel hub is cast by die casting technology in this paper. In practical production, the process parameters of die casting are hard to confirm, the time to adjust casting die is too long and the quality of casting product is difficult to accurately control. Therefore this paper tries to using die casting process numerical simulation technology, to virtual manufacture the aluminum alloy automobile wheel hub, which can forecast the die casting defects and help the engineers to make reasonable level of die casting process parameter.Die casting process simulation is an important method in modem foundry industry. It can carry out the useful forecast of the wheel hub casting quality, thus reducing the blindness in making die casting proeess; Analysis of process parameters can be optimized, thus ensuring the die casting quality and production efficiency. It also provides a new way for casting engineers to study casting foundry Process.This paper using orthogonal experiment design method and ProCAST software baggage as the tool of die casting process numerical simulation, view in the serious defects that influence wheel hub die casting quality, to decide the casting process parameter, and divide every casting process parameter into several level, which will be used in orthogonal experiment to design the simulations about the flow field and temperature field in die casting process, and base on these simulations to choose and ensure the optimized parameter.The biggest characteristics in this paper is using independent quantitative range analysis and variance analysis of orthogonal experiment to analyze die casting defects, base on these analysis, detect the weight of each process parameter to die casting defects, then synthetically think over the influence of whole casting quality by the weight of every die casting defect, to balance and choose the level of casting process parameter for seeking the whole quality optimization of casting.Base on the orthogonal experiment analysis, the optimal combination of die casting process parameter is that: casting temperature 600℃, casting velocity 45m/s, die temperature 180℃. By using this combination of process parameter, can reduce the defects such as gas trapping, oxide inclusion, shrinkage cavity and porosity, and shorten the production cycle of casting. Comparing with the practical production, the result of simulation is basically same as the actual production condition.To the same kind product, this simulation and analysis is the guidance and consult to work out the optimal parameter, design reasonable die and improve the quality of casting product.