VYSOKÉ UČENÍ TECHNICKÉ V BRNĚBRNO UNIVERSITY OF TECHNOLOGY

FAKULTA STROJNÍHO INŽENÝRSTVÍ

ÚSTAV STROJÍRENSKÉ TECHNOLOGIE

FACULTY OF MECHANICAL ENGINEERING

INSTITUTE OF MANUFACTURING TECHNOLOGY

NUMERICKÁ SIMULACE PLNĚNÍ A TUHNUTÍODLITKU

NUMERICAL SIMULATION OF MOLD FILLING AND CASTING SOLIDIFICATION

DIPLOMOVÁ PRÁCEDIPLOMA THESIS

AUTOR PRÁCE VLASTIMIL KOLDAAUTHOR

VEDOUCÍ PRÁCE Ing. VLADIMÍR KRUTIŠ, Ph.D.SUPERVISOR

BRNO 2008

FSI VUT 4

Abstrakt: ,

odlitku , analyzovat

tvaru odlitku

V

f . S ohledem na typ vzn

Abstract: The object of this diploma thesis is to analyze, persuant to numerical

simulation of current technology of production aluminous casting roller-reck V9X, causes of the rise of cold lap and laminations defects. Consequently, to work up a project of variant solution of the shape of casting so, as to come to elimination mentioned defects. This variant solving will be tested with numerical simulation as well. Fruitfulness of these designed changes will be verified by testing molten of the casting.

In terms of solve the problem the simulation of cycling of the mold and subsequently the filling of the casting will be effected. During the analyse of filling of the die the first phase of filling will be effected too.It means the movement of the piston throught the chambre. Simulation of solidification of the casting wont be effected because of the type of the defect.

Key words: High pressure die casting, Numerical simulation, Cold laps, Lamination

FSI VUT 5

:

vypracoval , s

a Datum

FSI VUT 6

:

.D. a Petrovi Nuskovi za rady

FSI VUT 7

Obsah:

1 .................................................................................................... 9

2 ................................................................................. 10

2.1 ................................................................. 11

2.1.1 horkou komorou ........................................... 11

2.1.2 ..................................... 12

2.2 ...................................................... 14

2.2.1 .................................................. 14

2.2.2 ................................................................ 15

2.2.3 ................................................... 16

2.2.4 .......................................................... 19

2.2.5 ............................................................. 19

2.2.6 ............................................................ 20

3 -odlitek .......................................... 20

3.1 ..................................................................... 21

3.2 ..................................................................... 22

3.3 .................................................................. 22

3.4 -odlitek ........................................... 23

3.5 .................................... 23

4 .................................................................... 24

4.1 ................................................................... 24

4.1.1 Zavalenina (cold lap) ........................................................... 24

4.1.2 .................................................... 28

4.1.3 ..................................................................... 30

4.1.4 ................................... 30

5 ................................ 32

5.1 ......................................................................................... 32

5.2 ....................................................................... 33

5.3 ........................................................................... 34

5.4 Dotlak ............................................................................................... 35

6 ......................................................................... 36

7 ................................................................... 36

8 Geometrie varianta 1 .................................................................... 37

8.1 Geometrie odlitku ............................................................................. 37

8.2 ............................................................ 38

8.3 Geometrie formy .............................................................................. 39

FSI VUT 8

8.4 .................................................................................... 41

9 ..................................... 42

10 - varianta 1 ....................................................... 43

10.1 ............................................................................... 43

10.2 .................................................................... 45

10.2.1 .......................................................................... 46

10.2.2 .................................................................................. 47

A. Odlitek 1 .............................................................................. 48

B. Odlitek 2 .............................................................................. 53

10.2.3 .............................................................. 56

11 Geometrie varianta 2 .................................................................... 58

12 varianta 2 ...................................................... 58

12.1 .................................................................... 58

12.1.1 .................................................................................. 59

A. Odlitek1 ............................................................................... 59

B. Odlitek 2 .............................................................................. 64

12.1.2 .............................................................. 67

13 ................................................................................................. 68

14 Literatura .......................................................................................... 72

FSI VUT 9

1

Jen

jako

schopen pomoci s

FSI VUT 10

2

V

v malou

vs = 40-60 m/s) a k v formy neboli v

,

formy.

V

v

. z

1.

k

FSI VUT 11

Obr. 1 [2]

2.1

stroje

z

horkou komorou (hot chamber) a studenou komorou (cold chamber). Stroj s horkou

slitin s ,

jako jsou slitiny hl s Tyto ma ,

s

2.1.1 horkou komorou

horkou . Stroj

otvorem do komory k

FSI VUT 12

Obr. 2 horkou komorou [3]

2.1.2

Princip stroje se studenou komorou je nz otvorem pro a

skrz vtokovou soustavu do dutiny formy.

-

FSI VUT 13

komorou je schematicky zobrazen na 4.

Obr. 3 horkou komorou [3]

Obr. 4 [4]

FSI VUT 14

2.2

, ch. Na obr. 5 je schematicky

[5]

Obr. 5 - kokila[5]

2.2.1 stroje

slitiny, tvar a velikost ov

vypo

kSS

FkSpF

L

L

LLU....

FSI VUT 15

Obr. 6 [5]

sou v tabulce 1[5]

T

Hodnota Konstanty

stroje.

2.2.2

i.

k

-0,3, -

FSI VUT 16

Obr. 7 [5]

stroje, aby ohledem na

ustavy vede k

odlitku z

2.2.3

z

8

FSI VUT 17

Obr. 8 [5]

pore

z

tv

GS

'..'

v m hodnoty

FSI VUT 18

a pohybuje se

v

Tab. 2

proudu

,

le [3]

formy [3]

FSI VUT 19

2.2.4 emperace

Chladi s(viz. 2.1.1).

- a jeho teplota se pohybuje

v

2.2.5

z v

odlitku.

v duti

pohybuje cca od 0,05 do 0,1 mm ka 20 mm. V

obvykle

Obr. 10

FSI VUT 20

2.2.6

(valchy, vlnovce) nebo (obr 11).

Obr. 11 [6]

3 -odlitek

k forma -

V

[7]

FSI VUT 21

3.1 stup

dnotku plochy

o

x

TkAq

Kde: q [W] A plocha, p [m2] K T teplota [K] x [m]

toku. [7]

o

condthR

Tq kde

kA

xcondthR

Tento vztah ourierovu rovnici, je tok,

ourierova rovnice lze pak v [7]

FSI VUT 22

3.2

ourierovy rovnice spolu s

libovolnou teplotou na

[7]

mnoha modifikacemi a kombinacemi s Fo

3.3

v

proudu kovu bez

[7]

kde T a TS [W/m2K]

FSI VUT 23

3.4 -odlitek

el

odlitky.

f

odlitku.

rsnost V

-kov.

izolant s

,

kovu. [8]

3.5

v

chyby v k

FSI VUT 24

4

To, , ,

rovnou v

4.1

V ch

4.1.1 Zavalenina (cold lap)

v

formy s Takov

, 12 a 13

Obr. 12 Z Obr. 13 Vada v

Z z praxe je

s

k

FSI VUT 25

odlitku

v

u je 1.5 mm. s [9]

Tvar odlitku

m faktorem mnoha m na

[9]:

- -

- - (obr. 14) -

zvoleno - v

Obr. 14

na odlitku s

, , dutiny, : ,

kg pohybuje v 50 100 msec.

se zj [9]

FSI VUT 26

TTT

SZTTKt

df

fi.)(

.

kde: K = konstanta Ti = teplota kovu v Tf Td = teplota kokily formy procent

v v tabulce 2.1 v kapitole 2.2.2.

Tab. 3 O [3]

Tab. 4 3]

, kdy rychlost v

fl

FSI VUT 27

: o

, [9]

2

oje a kvalitu konstrukce formy z a

[6]

Obr. 15 P 2 diagramu []

Teplota formy

t

: [9]

- - - Doba cyklu

FSI VUT 28

odvodu tepla z , m

odlitku.

Teplota kovu

:

teplot v [9]

4.1.2 lamination)

spoj vznikne v

Obr. 16 je

FSI VUT 29

16 ukazuje situaci proudy kovu 1 a 2 dotekly do

3 m proudem proudy 1 a 2,

Tento

17).

Obr. 17

V zvyt , 18. Je proto nutn

ce

Obr. 18

FSI VUT 30

4.1.3

v odlitku

0]

Obr. 19

4.1.4

Porezita sou y

dutiny formy, ale tak

chladi [11]

kte

-

. [11]

FSI VUT 31

. Obr 20 m za , kdy je vzduch z dutiny

Obr. 20 [2]

, , v ,

uzav

Obr. 21 [12]

zase Ten

komory.

Obr. 22 [12]

FSI VUT 32

5

pozorovat pod

-Group. Tento program

, jsou:

- - - - - - Dotlak

Program Final Element Method),

s

5.1

ch ch ro et

formou a odlitkem tak i mezi formou a

23.

FSI VUT 33

Obr. 23

5.2

odlitku. Jsme-

procesu. je , z jednou

, Simulaci rychlosti

kovu v z

Obr. 24

FSI VUT 34

5.3

Jednou z v

vtoku a

Obr. 25 a) b) c)

FSI VUT 35

5.4 Dotlak

odlitku v V

v 26.

Obr. 26

FSI VUT 36

6

(varianta1). Pro eliminaci

, respektive (varianta2)

software ProCAST.

7

,

,

27 a 28.

Obr. 27

Obr. 28

FSI VUT 68

13

o je difuz br. 45)

avaleninu. V

z 49)

ou Proto byl ,

,

tak 63 a 64

druhou.

rychlostech mezi variantou 1 a 2

FSI VUT 69

Obr. 63 Odlitek varianta 1 s

Obr. 64 Odlitek varianta 2

FSI VUT 70

obou p plot u obo

65.

FSI VUT 71

respe , .

K a to , .

dosti komplikovan .

FSI VUT 72

14 Literatura

[1] : PAM - CAST/Simulor - -9, Brno 1997,

str.346-348 [2] URL: http://www.mueller-weingarten.de [3] HERMAN, A.:

http://u12123.fsid.cvut.cz/?udaj=predmet&id=C36010 [4] KALPAKIAN, Serope SCHMID S. R.: Manufacturing

engineering and technology 5th edition, Pearson Education, Inc., 2006

[5] HERMAN, A.:

na internetu: http://u12123.fsid.cvut.cz/podklady/MPL/konstrukce_forem.pdf

[6] Barbora

internetu: http://u12123.fsid.cvut.cz/?udaj=predmet&id=C36010 [7] HATTEL, Jesper: Fundamentals of numerical modelling

of casting processes, Polyteknisk Forlag, 2005 [8] FREDERIKSSON Hasse - AKERLIND Ulla: Materials processing

during casting, John Wiley & sons, Ltd, 2006 [9] WALKINGTON, W. G.: Die casting defects, Illinois: North

American Die Casting Association, 1997 [10] KUZMA [11] K Konstrukce forem pro odlitky

. 2007 2-3 /, s. 81

[12] HONG, Jun Ho: Investigation on the flow pattern in the shot

sleeve of the cold chamber HPDC process, world foundry congress 06, Casting the future