柴油機(jī)進(jìn)氣管鑄造設(shè)計(jì)【說明書+CAD】

柴油機(jī)進(jìn)氣管鑄造設(shè)計(jì)【說明書+CAD】,說明書+CAD,柴油機(jī)進(jìn)氣管鑄造設(shè)計(jì)【說明書+CAD】,柴油機(jī),氣管,鑄造,鍛造,設(shè)計(jì),說明書,仿單,cad JMaterSciTechn01，V0124 No1，2008 Thin-Wall Aluminum Die-Casting Technology for Development of Notebook Computer Housing Chang-SeogKangt，Jae一k Cho，Chang-Yeol Jeong,SeWeon Choi and Young-Chan IGm Korea Institute of Industrial Technology，Gwangju，Korea Manuscript received September 3，2007 65 Siliconbased aluminum casting alloys are known to be one of the most widely used alloy systems mainly due to thei r superior castlng characteristics and unique combination of mechanicaI and physicaI properties Howevermanufacturing of thinwalled aluminum diecasting components，Iess than I0 mm in thicknessis generally known to be very difficult task to achieve aIuminum casting alloys with high fluidityThereforein this studythe optimal diecasting conditions for producing 297 mm x 210 mm x 07 mm thinwalled aluminum component was examined experimentally by using 2 different gating systems，tangential and split typeand vent designFu rthermore，computational solidification simulation was also conductedThe results showed that split type gating system was preferable gating design than tangential type gat ang system at the pomt of view of soundness of casting and distortion generated after solidificationIt was also found that proper vent design was one of the most important factors for producing thinwaI|casting components because it was important for the fullment of the thinwall cavity and the minimization of the casting distortion KEY WORDS：Aluminum；Thin-wall diecasting；Notebook computer housing；Cold chamber diecasting machine 1Introduction Among the aluminum casting alloysthe A1一Si based alloy systems are one of the most widely used alloy systems because of their unique characteristics such as 10w density，moderately high strength，and good castability,etc1 3jRecently,the demand for lightweight alloys i11 electricelectronic and autoHIo bile component housings using aluminum has been greatly increased mainly because it is lightweight hav ing high damping capacity and dent resistance conl pared to plastics Howeverit is generally known that manufactur ing of thinwall aluminum component with a thick ness less than 10 mm by using high pressure die cast ing process is quite difficult due to its low fluidity This leads to the liinit,ed application of the aluminum alloy in the fields of housing of electricelectronic components such as notebook computer and cellular phone，etcTherefore，in this study，diecasting pro cess technology for the production of thinwall alu minum components based on the investigation of the optimal die design including runners and gating sys tem and casting conditions was investigatedMore over，experimental examinations of gating design el- fects on the fabrication processing of sound thinwall aluminum notebook housing with a thickness of less than 08 nlnl 2Experimental Prior to the actual diecasting experimentcasting simulation vcas conducted to set up the diecasting and melt conditionsDiecasting die made out of H13 tool steel for the thinwall notebook housing in size of 210 Himx297 nlnl07 innl was designed and fabricated for the experiment As shown in Fig1、 十 PhD，to whom co r11e8pondence should be addressed Emaih cskan97kitechrekr the 2 different types of gating system，tangential type and split type，were used for this investigation A commercial ALDCl2 aluminum diecasting alloy(A1一(9612)si一(15 35)Cu，Table 1)was melted up to 780。C and the die was heated up to 230。C before the die castingThe major specifica tions of the cold chamber diecasting machine fFig2)， used for this study are shown in Table 2Molten alu minum alloy was injected into the die cavity under the conditions of 035 ms in injection speed until the plunger traveled up to 370 Him in shot sleeve and then the in 1iectionspeed was accelerated inearly to the high injection speed of 20，25，303540 and 45 ms fronl 370 inm to 390 Him in shot sleeveTa ble 3 shows the summary of diecasting conditions for this investigation 3Results and Discussion The solidi蠡cation simulation was conducted for 2 different gate designs，tangential and split type prior to the diecasting experimentThe flow pattern and temperature distribution during filling of aluminum melt with the gate designs studied are shown in Fig3 It was found that both gate designs exhibited quite uniform melt flow throughout the filling of the cav ityHowever，the tangential type gate design re suited in the melt temperature dropped area f circled iil Fig3(a)at the last stage of filling while tile split type gate design allowed the melt to fill the cavity above the liquidus temperature As mentioned，actual diecasting experiments were conducted for the notebook computer housing in size of 210 miD_297 nlnlX07 toniFigure 4 shows the re sultant castings with varied high speed injection from 20 to 45 ms while 10w speed injection was fixed to 035 msAs shownboth gate designs allowed filling the casting with high speed injection of more than 30 msHowever，less than 30 ms of high speed injection failed to fill the thinwall cavityIt was 萬方數(shù)據(jù) 66 JMaterSciTechn01，V0124 No1，2008 Table 1 Chemical compositions of ALDCl2 alloy(in wt pct) Table 2 Specification of diecasting machine 5250 490 砂70 Table 3 Diecasting experiment conditions 780 230 20，25，30，35，40，45 035 Fig1 Schematic illustration notebook housing(210 mmx297 IllIllXo8 nlm)and 2 different gate designs：(a)tan gential type，(b)split type Fig2 High speed diecasting machine 萬方數(shù)據(jù) E E 、 C Q 芑 凸 JMaterSciTechn01，V0124 No1，2008 Fig3 Simulation results of 2 different gate designs：(a)tangential type，(b)split type Fig4 Diecasting results by varying the high speed injection：(a)tangential type，(b)split type Distance，mm Fig5 Distortion of tangential and split type gating sys tem after the removal of gates also found that the tangential type gate design was not able to 61l the overflow even at the highest injec tion speed used for this investigationMoreover，the tangential type gating system resulted in more dis tortion of the casting after the removal of the gate 67 In Fig5，the amount of distortion measured after removal of each gating system was displayedThe result clearly showed that the tangential type gat ing system could resulted in more severe distortion than split typeSince notebook housing fabricated in this research was only 07 mm in thickness，the stress build up because of the shrinkage of casting after the completion of solidification was an important factor to consider for the mass production of the notebook housingTherefore，it was concluded that the split type gate design was better than the tangential type because of the aforementioned matters Howevereven with split type gate design there were casting defects such as flow line and misrun dur ing diecastingTherefore，two major modifications were introducedOne was the increase of the over flow and vent sizesThe volume of the overflow was increased about 70ffrom 4400 mm3 to 7500 mm3) and the overflow ingate length was also increased frOln 135 mm to 30 mm in total length for the better flow of air in the die cavityMoreover，upper part of sleeve was machined to have inclined slope as shown in Fig6 萬方數(shù)據(jù) 68 JMaterSciTechn01，V0124 No1，2008 Fig6 Schematic illustration of the inclined slope sleeve Fig7 Thinwall notebook housing with a thickness of O7 mill Gate system Location Fig8 The thickness of thinwall notebook housing to minimize the turbulence and air entrapment inside of the sleeve during in iection Because the sleeve WaS filled with aluminum less than 30fminimum of 40 of sleeve filling is recommended in die，casting pro cess in fieldl resulting large amount of entrapped air and high turbulence during injection L4JAs the Fig6 shows，the machined slope would help air inside of the sleeve to flow out more easily during in tha土iectionSO the air entrapment in the melt would be minimized With-two modifications mentioned earlier，sound thin wall notebook housing casting with less defect WaS successfiflly fabricated(Fig71There found to be less flow line，crack and misrun defects in the castingThe thickness of the casting was measured fFig81In left figure，the locations of the thickness measured and are shown and the right figure shows the nleasured thick EE、o亡芏。I uI 萬方數(shù)據(jù) JMaterSciTechn01，V0124 No1，2008 ness of the castingThe thickness was found to be quite uniform and average thickness of 067 nlnl was obtained Because the casting was so thin，less than 07 innl， the e 一iection fronl the die afterl the solidification becanlevery important Tbin wal casting could be bent or even cracked during the ejection；therefore，the number of ejector pin and its 1ay out were very critical in die designMoreover，the use of die temperature controller WaS also an important factor for fulfillment of die cavity for thinwall diecastingIt was foIund that without the die temperature controllerthe die WaS not heated up SOfficiently even with more than 20 times of injectionWhen the die did not be heated up to appropriate temperature，the melt would be rapidly cooled down when it injected inside of the cold die cavityAs a resultsevere casting defects in eluding misrun and cracks were exhibited without die temperature contr01 4Conclusion (1)Between tangential and split,type gate designs， split type gating system WaS found to be better for thinwall diecasting because the melt flows more uni formly inside the die cavity (2)As the melt reached the ingate，the high speed injection needed to be higher than 30 mSprefer ably 45 msfor sound thinwall diecasting in size of 69 notebook computer housing (3)The thickness was uniform throughout the casting and average thickness of 067 nUll was ob tained (4)For thinwall aluminum diecasting，the loca tion and the size of air vent and overflow were impor tant factors for minimizing the flow line and inisrun defects in the casting (5)Inclined slope sleeve design WaS helpful for air entrapped inside of sleeve to flow out during injection (6)Because the casting volume WaS quite small，it is important to COntrol the die temperature 38 high 38 possible Acknowledgement This work was supported by Korea Institute of Indus trial Technology and Cwangju Metropolitan City through “The Advanced Materials and Components Industry De velopment Program” 【2 3 【4 REFERENCES Microstructure and Properties of Aluminum Allqys The Japan Instof Light Metals，1991233 GKSigworth：AFS TraIIS198391。7 JEGruzleski and Bernard MClosset：AFS199013 WGhlkington：Die Casting DefectsNADCA 1997 萬方數(shù)據(jù) Thin-Wall Aluminum Die-Casting Technology for Development of Notebook Computer Housing 作者： Chang-Seog Kang， Jae-Ik Cho， Chang-Yeol Jeong， Se-Weon Choi， Young-Chan Kim 作者單位： Korea Institute of Industrial Technology, Gwangju, Korea 刊名： 材料科學(xué)技術(shù)學(xué)報(bào)（英文版） 英文刊名： JOURNAL OF MATERIALS SCIENCE & TECHNOLOGY 年，卷(期)： 2008，24(1) 引用次數(shù)： 0次 參考文獻(xiàn)(4條) 1.Microstructure and Properties of Aluminum Alloys 1991 2.G K Sigworth 查看詳情 1983 3.J E Gruzleski.Bernard M Closset 查看詳情 1990 4.W G Walkington Die Casting Defects 1997 相似文獻(xiàn)(3條) 1.期刊論文 Young-Chan Kim.Chang-Seog Kang.Jae-Ik Cho.Chang-Yeol Jeong.Se-Weon Choi.Sung-Kil Hong Die Casting Mold Design of the Thin-walled Aluminum Case by Computational Solidification Simulation -材料科學(xué)技術(shù)學(xué)報(bào)（英文版）2008,24(3) Recently, demand for the lightweight alloy in electric/electronic housings has been greatly increased. However, among the lightweight alloys, aluminum alloy thin-walled die casting is problematic because it is quite difficult to achieve sufficient fluidity and feedability to fill the thin cavity as the wall thickness becomes less than 1 mm. Therefore, in this study, thin-walled die casting of aluminum (Al-Si-Cu alloy: ALDC 12) in size of notebook computer housing and thickness of 0.8 mm was investigated by solidification simulation (MAGMA soft) and actual casting experiment (Buhler Evolution B 53D). Three different types of gating design, finger, tangential and split type with 6 vertical runners, were simulated and the results showed that sound thin-walled die casting was possible with tangential and split type gating design because those gates allowed aluminum melt to flow into the thin cavity uniformly and split type gating system was preferable gating design comparing to tangential type gating system at the point of view of soundness of casting and distortion generated after solidification. Also, the solidification simulation agreed well with the actual die-casting and the casting showed no casting defects and distortion. 2.外文期刊 Chang-Seog Kang.Jae-Ik Cho.Chang-Yeol Jeong Thin-Wall Aluminum Die-Casting Technology for Development of Notebook Computer Housing Silicon-based aluminum casting alloys are known to be one of the most widely used alloy systems mainly due to their superior casting characteristics and unique combination of mechanical and physical properties.However,manufacturing of thin-walled aluminum die-casting components,less than 1.0 mm in thickness,is generally known to be very difficult task to achieve aluminum casting alloys with high fluidity.Therefore,in this study,the optimal die-casting conditions for producing 297 mm210 mm0.7 mm thin-walled aluminum component was examined experimentally by using 2 different gating systems,tangential and split type,and vent design.Furthermore,computational solidification simulation was also conducted.The results showed that split type gating system was preferable gating design than tangential type gating system at the point of view of soundness of casting and distortion generated after solidification.It was also found that proper vent design was one of the most important factors for producing thin-wall casting components because it was important for the fulfillment of the thin-wall cavity and the minimization of the casting distortion. 3.外文期刊 Young-Chan Kim.Chang-Seog Kang.Jae-Ik Cho Die Casting Mold Design of the Thin-walled Aluminum Case by Computational Solidification Simulation Recently,demand for the lightweight alloy in electric/electronic housings has been greatly increased.However,among the lightweight alloys,aluminum alloy thin-walled die casting is problematic because it is quite difficult to achieve sufficient fluidity and feedability to fill the thin cavity as the wall thickness becomes less than 1 mm.Therefore,in this study,thin-walled die casting of aluminum(Al-Si-Cu alloy:ALDC 12)in size of notebook computer housing and thickness of 0.8 mm was investigated by solidification simulation(MAGMA soft)and actual casting experiment(Buhler Evolution B 53D).Three different types of gating design,finger,tangential and split type with 6 vertical runners,were simulated and the results showed that sound thin-walled die casting was possible with tangential and split type gating design because those gates allowed aluminum melt to flow into the thin cavity uniformly and split type gating system was preferable gating design comparing to tangential type gating system at the point of view of soundness of casting and distortion generated after solidification.Also,the solidification simulation agreed well with the actual die-casting and the casting showed no casting defects and distortion. 本文鏈接：http:/ 下載時(shí)間：2010年5月23日