Optimization Of Die Casting Process For Automotive Engine Frame Based On CAE

Die casting,as a special casting,has the characteristics of high surface finish and high dimensional accuracy,and has been developed rapidly in the manufacturing industry.However,in the actual production of the automobile engine frame of an enterprise,there are some small cracks on the surface of some die-casting products visible to the naked eye.It not only makes the overall quality of die-casting products decline,but also causes potential safety hazards in the use of die-casting products.It is found that there are holes under the crack defect by dissection.It is very likely that the holes defect under the stress will cause the upper surface of die casting products to be pulled apart,and finally form the small crack defect visible to the naked eye.Therefore,the automobile engine frame can not meet the expected standard of the enterprise in actual production.In order to solve the problem of defects caused by improper setting of die casting process parameters and avoid the limitation of traditional trial-and-error method,this subject hopes to analyze and optimize the die casting process of automotive engine frame by using CAE simulation analysis software ProCAST,so as to reduce the generation of hole defects,prevent the occurrence of small cracks on the upper surface of die casting products,and improve the whole product of die casting products.Quality.Firstly,the structure design and process analysis of die casting products are carried out.The structure design involves chamber capacity,pouring system,overflow system,cooling system,etc.The process analysis involves die temperature,insert temperature,injection speed and pouring temperature.Then,the pre-processing,including meshing and alloy parameters calculation,as well as CAE simulation analysis of die casting cycle,was carried out.Finally,the thermal physical parameters of the actual alloy were obtained,the thermal balance rule of the die was obtained,and the corresponding temperature was extracted as the initial temperature of the die in the orthogonal experiment.Next,orthogonal experiments were carried out,taking the insert temperature,injection speed and pouring temperature as influencing factors,solidification time,entrainment volume and shrinkage hole defects as experimental indicators.The optimal die casting process parameters were obtained as insert temperature 260 C,injection speed 4.5 m/s and pouring temperature 650 C.At the same time,because the exterior surface of die-casting products is in direct contact with the die,it is necessary to study the working temperature of the die deeply,which involves the surface distance,pouring temperature and cooling water velocity and temperature in the cooling system,etc.It is obtained that the cooling water velocity has a great influence on the working temperature of the die.Finally,considering the fact that the temperature of liquid alloy decreases in the process of transporting and pouring,it is reasonable to raise the pouring temperature to 660 C,and verify the actual production.Finally,the die casting products with good quality and bright and clean surface can be obtained.In summary,this project successfully uses the CAE simulation analysis software ProCAST to optimize the die casting process parameters of the automobile engine frame,reduce the occurrence of hole defects,that is to say,solve the problem of small cracks on the surface of the automobile engine frame,and analyze the factors affecting the temperature field of the die,which provides a theoretical basis for guiding the actual production process.In addition,it shortens the test time,reduces the test cost and improves the economic benefit of the enterprise,which shows that CAE simulation analysis technology has practical application value and important engineering significance for die casting production.