Numerical Simulation and Experimental Validation of Squeeze Casting of AlSi9Mg Aluminum Alloy Component with a Large Size |
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| Authors: | Jufu Jiang Jing Yan Yingze Liu Guoquan Hu Ying Wang Changjie Ding Dechao Zou |
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| Affiliation: | 1.School of Materials Science and Engineering, Harbin Institute of Technology, Harbin 150001, China; (J.Y.); (Y.L.); (G.H.);2.School of Mechatronics Engineering, Harbin Institute of Technology, Harbin 150001, China;3.Dalian Innovation Die-Casting Co., Ltd., Dalian 116600, China; (C.D.); (D.Z.) |
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| Abstract: | The squeeze casting process for an AlSi9Mg aluminum alloy flywheel housing component was numerically simulated using the ProCAST software, and orthogonal simulation tests were designed according to the L16 (4) 5 orthogonal test table to investigate the alloy melt flow rule under four factors and four levels each of the pouring temperature, mold temperature, pressure holding time and specific pressure, as well as the distributions of the temperature fields, stress fields and defects. The results showed that the flywheel housing castings in all 16 test groups were fully filled, and the thinner regions solidified more quickly than the thicker regions. Hot spots were predicted at the mounting ports and the convex platform, which could be relieved by adding a local loading device. Due to the different constraints on the cylinder surface and the lower end surface, the solidification was inconsistent, the equivalent stress at the corner junction was larger, and the castings with longer pressure holding time and lower mold temperature had larger average equivalent stress. Shrinkage cavities were mainly predicted at mounting ports, the cylindrical convex platform, the peripheral overflow groove and the corner junctions, and there was also a small defect region at the edge of the upper end face in some test groups. |
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| Keywords: | squeeze casting numerical simulation temperature field stress field defects prediction |
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