摘 要

低壓鑄造是一種先進(jìn)的鑄造生產(chǎn)工藝，隨著機(jī)械行業(yè)的不斷發(fā)展，低壓鑄造在國(guó)內(nèi)外的鑄造生產(chǎn)中也得到了很大的發(fā)展[1]，出現(xiàn)了一些新技術(shù)、新工藝，從而提高了低壓鑄造產(chǎn)品的質(zhì)量，取得了高的成品率。它是介于壓力鑄造與重力鑄造之間的一種鑄造方法，具有金屬液充型平穩(wěn)，鑄件組織致密，工藝出品率高，易實(shí)現(xiàn)自動(dòng)化等優(yōu)點(diǎn)，特別適用于復(fù)雜壁鑄件的生產(chǎn)，在現(xiàn)代工業(yè)中應(yīng)用非常廣泛[2]。
隨著計(jì)算機(jī)硬件水平的提高，鑄造CAE軟件對(duì)實(shí)際生產(chǎn)的指導(dǎo)作用日益顯著。低壓鑄造領(lǐng)域也開始使用它們來優(yōu)化和改進(jìn)工藝，以便提高產(chǎn)品質(zhì)量、降低廢品率、減少冒口損耗、提高成品率、縮短試制周期、降低生產(chǎn)成本、減少工藝設(shè)計(jì)對(duì)人員經(jīng)驗(yàn)的依賴、保持工藝設(shè)計(jì)水平穩(wěn)定等[3]。
本次畢業(yè)設(shè)計(jì)以六缸液壓泵體為研究對(duì)象，介紹了低壓鑄造的一般步驟。首先根據(jù)給定的二維零件圖，利用三維建模軟件UG NX4.0 畫出六缸液壓泵體的三維實(shí)體模型。然后，通過對(duì)該零件的結(jié)構(gòu)工藝性進(jìn)行分析，設(shè)計(jì)澆注系統(tǒng)，確定可行的工藝方案。同時(shí)，通過用AnyCasting 鑄造模擬軟件，對(duì)鑄件的鑄造工藝進(jìn)行分析并優(yōu)化。最后，通過模具設(shè)計(jì)2D、3D CAD 軟件，對(duì)模具關(guān)鍵部件進(jìn)行三維造型，并繪制模具二維圖。


關(guān)鍵詞：泵體，低壓鑄造，模具設(shè)計(jì)，鑄造CAE，分析模擬













ABSTRACT

Low pressure casting is the advanced cast technology. As the development of the mechanical industry, low pressure casting is developing quickly in casting production at home and abroad. Meanwhile, the appearing of the new technique and the new process improves quality of products under low pressure casting and achieves high ratio of healthy products. Low pressure casting, which is used widely in modern industry, is a casting method between pressure casting and gravity casting. It has the advantage of stable casting mould filling, compact casting structure, high process yield rate and readily automated operation, and is especially suitable for production of complex wall castings.
With the improving level of computer hardware, foundry CAE software plays an increasingly important role in the practical production. In the field of low pressure casting, it is begin to used to optimun and improve process, so that improving product quality, lowing reject rate, reducing loss of riser, increasing probability, shortening the trial-produce cycle, reducing the cost, lessening the process design ‘s dependence on the experience of the designers, keeping stable of the level of the process design and so on.
The graduation project takes the hydraulic six-cylinder pump body as research object, introducts general steps of low pressure casting. Firstly, ding the 3D solid model of the hydraulic six-cylinder pump body with 3D modeling software UG NX 4.0 according to the 2D part drawings. Secondly, designing pouring system through analyzing the stucture technics of part, and determining feasible process plan. As the same time, analyzing and optimizing the casting process of the cast with AnyCasting simulation software. Lastly, 3D designing key parts of die and darwing 2D darwing of die with 2D、3D CAD soft.


Key words：pump body, low pressure casting, die design, casting CAE, analysis simulation






目 錄

中文摘要 Ⅰ
ABSTRACT Ⅱ
1緒論 1
1.1 引言 1
1.2 低壓鑄造國(guó)內(nèi)外的研究現(xiàn)狀及發(fā)展趨勢(shì) 1
1.3 泵體零件的生產(chǎn)情況 1
1.4 課題的研究目的及意義 2
1.4.1 課題的研究目的 2
1.4.2 課題的研究意義 2
1.5 課題的主要工作 2
2 工藝分析及模具設(shè)計(jì) 3
2.1 鑄件工藝設(shè)計(jì) 3
2.1.1 鑄件工藝性分析 3
2.1.2 鑄件的技術(shù)要求 4
2.1.3 加工余量、最小鑄出孔、收縮率、鑄造斜度 4
2.1.4 鑄件在鑄型中的位置 5
2.1.5 鑄件的凝固 6
2.1.6 澆注系統(tǒng)的設(shè)計(jì) 7
2.2 鑄型工藝設(shè)計(jì) 8
2.2.1 鑄型尺寸的計(jì)算 8
2.2.2 鎖型力（合型力）的計(jì)算 9
2.2.3 鑄型的排氣 9
2.2.4 鑄型充型指示系統(tǒng)的設(shè)置 9
2.3 鑄造工藝 10
2.3.1 工藝過程 10
2.3.2 升液管的準(zhǔn)備 10
2.3.3 保溫坩堝的準(zhǔn)備 10
2.3.4 鑄型的準(zhǔn)備 10
2.3.5 澆注工藝 10
2.4 鑄件常見缺陷及防止方法 12
2.4.1 孔洞與渣孔 12

2.4.2 裂紋 12
2.4.3 表面缺陷 12
2.4.4 精度與性能 13
2.5 鑄件常見缺陷及防止方法 13
2.5.1 設(shè)備的選用 13
2.5.2 設(shè)備的校核 13
2.6 模具設(shè)計(jì) 14
2.6.1 模具組裝圖 14
2.6.2 成型零件的設(shè)計(jì) 15
2.6.3 結(jié)構(gòu)零件的設(shè)計(jì) 17
2.7 繪制主要零件的二維圖 18
2.8 關(guān)鍵公差與配合、表面粗糙度、形位公差的技術(shù)要求 18
2.8.1 關(guān)鍵公差與配合 18
2.8.2 表面粗糙度 19
2.9 選材及熱處理要求 20
2.9.1 對(duì)材料的要求 20
2.9.2 材料的選擇及熱處理 20
3 工藝模擬及優(yōu)化 22
3.1 AnyCasting介紹 22
3.1.1 AnyCasting的特點(diǎn) 22
3.1.2 AnyCasting的模塊 22
3.1.3 工作流程 23
3.2 工藝模擬及優(yōu)化 23
3.2.1 anyPRE前處理 23
3.2.2 anySOLVER模擬引擎 30
3.2.3 anyPOST后處理 31
3.2.4 分析結(jié)果，選擇最優(yōu)方案 32
4 結(jié)論 34
致謝 35
參考文獻(xiàn) 36