锌合金压铸数值模拟及其热流道技术分析-numerical simulation of zinc alloy die casting and analysis of hot runner technology.docx

II II Study of Numerical Simulation and Hot Runner Technology for Zinc Alloy Die Casting Abstract Due to the high mechanical property and the good casting property, zinc alloy occupies an irreplaceable position in hardware accessories manufacturing. For now, most of the domestic casting factories are facing the awkward situation of both high cost and low efficiency, because of the main way to design die casting mould is only rely on experience which is necessary to repeatedly test, repair and optimize. In addition, through analysis the cost and quality for zinc die casting runner, it can be found that the die-casting hot runner has an important effect on the hands of controlling cost and improving quality. Thus, the paper attempts to propose the corresponding countermeasure and the measure in view of above question, and mainly carried on following research： Application of numerical simulation technology for zinc alloy die casting Numerical simulation on zinc alloy die casting also have great difficulties because of most castings were thin-wall, especially the size of gating system. In this paper, we simulate die casting filling process of zinc alloy parts with FLOW 3D software to predict the location of defects so that the gating system and process condition can be optimized. The main contents include defecting and fixing errors in STL geometry files, mesh generation and model setup. Design and optimization of casting system for zinc alloy die casting Firstly, the paper study on a cover plate of zinc alloy product, for the casting’s characteristics of shape and size, taper casting system and process condition parameters were designed and optimized according to the simulation results. By comparing the simulation results after optimization with the experiment results, the rationality of new project were validated. Moreover, the experiment results also validate the feasibility of the optimal design and the reliability of numerical simulation on the die casting process.