Study On The Simulation And Manufacturing Process Of Squeeze Casting Of The Aluminum Automobile Inner Door Panel

With the application of Lightweight materials,auto-body panel may receive a great weight reduction.Currently the stamping and welding process is used to manufacture the aluminum body which is in similar to steel.This process involves of aluminum sheets and comlex molds,which means the costs are relatively high.In contrast,through the adoption of casting,it is economical to fabricate the automobile cover.Nevertheless,it is a great challenge to manufacter such a thin-walled structure with complex morphology.lt is reported that only a couple of coMPanies could product such kind of aluminum castings in application of high pressure die-casting with a vacumm assistant facility.Squeeze casting integrates the features of casting and forging,which makes it possible to fabricate the parts with fine grain size,high mechanical performance,good surface quality as well as less material to be removed.(1)The squeeze casting mold is designed with the application of CAE method. Heating tubes are arranged under the instruction of casting CAE software.Then,the strengths of punch and matrix are checked respectively with the structure analysis software.(2)The squeeze casting process is simulated in use of casting CAE software on different process conditions(pouring temperature,die temperature and punch speed).The termperature distribution of filling process under different conditions is analysed.lt is discovered that with the combination of pouring temperature(no less than680℃),die temperature(no less than310℃),punch speed(24mm/s), the aluminum inner auto-pannel could be manufactured with a integrate shape.(3)The trial fabrication of inner auto-pannel is accomplished in3batch with use of comerical ADC-12alloy and AlX.The evalution of the quality of aluminum panel is carried out in terms of tensile testing, metallographic oberservation, environmen-tal scanning electron microscopy (ESEM) and Auger Electron Sprctroscopy.The casting with a relatively high tensile strength and good surface quality could be ac-hieved in conditions of pouring temperature730℃, die temperature310°C and pres-sure27MPa.