A Study on the Computer-aided Simulation of A390 Aluminum Brake Disk 劉宗原、胡瑞峰 劉勝安
E-mail: 9314771@mail.dyu.edu.tw
ABSTRACT
This study made use of the computer-aided engineering(CAE) analysis software to simulate the A390 aluminum alloy brake disk cast by CO2 sand mold and to find out the casting shrinkage defects. The simulation also tried to get the resolution of eliminating the defects by using different riser modulus and different chiller shape for the brake disk. In addition of computer simulation, the real brake disk castings were poured to be compared with the simulation results. The main accordance of riser modulus is 1.2 times of the brake disk casting modulus, and the riser design adopted the modulus values near the main riser modulus to investigate the effects of riser on the casting. As the riser could not feed the casting successfully, the added chillers were designed to compensate the function and promote the riser's feeding through the directional solidification. Finally, the casting yield was optimized by the simulation of OptiCast module of the CAE software for the A390 aluminum alloy brake disk. The simulation results show that there exists similar shrinkage defects between the pressurized gating system with a gating ratio 1:2:1 and the unpressurized gating system with a gating ratio 1:2:2. On the riser modulus, the riser with a 10 modulus had adequate feeding distance for the casting, and it did not need a chiller design. But, there existed a short and inadequate feeding distance for the riser with a 8 modulus, and thus needed a chiller design to resolve the problem. As for the riser with a 6 modulus, it showed an impossible feeding result for the brake disk castings whether with a chiller design or not. Finally, the CAE simulation and the practical castings poured all reveal the chillers having a round disc shape design were better than the chillers with a rectangular shape on establishing the directional solidification for the casting .
Keywords : A390 Aluminum Alloy, Brake Disk, Computer-aided Engineering (CAE), Riser, Chiller, Modulus, Feeding Table of Contents
封面內頁 授權書………....iii 中文摘要………
……….... .v 英文摘要………... .vi 誌謝………
………...viii 目錄………... .ix 圖目錄………
………... xii 表目錄………... .xv 符號說明………
………... xvi 第一章 前言………... 1 第二章 文獻 探討………... ...3 2.1 關於碟盤………...………... 3 2.2 材料與 造模……….………...………... 4 2.2.1 A390.1鋁合金………..………... 4 2.2.2 CO2砂 模法.……..………..…….………. ...6 2.3 澆流道系統…….………..………... 6 2.3.1 澆口設計…
….…………..………... 8 2.3.2 澆口杯………..………. ...9 2.3.3 豎澆道………
……..………. ...10 2.3.4 橫流道………..………. ...10 2.3.5 進模口………
…………..…………... 11 2.3.6 澆口比原理………..………. ...11 2.3.7 冒口………
………..………. ...12 2.3.8 冷鐵………....………... ...15 2.4 電腦輔助模擬軟體……..………
……..………….. ....16 2.4.1 軟體的發展………..………. ...16 2.4.2 軟體基本架構………..…
………. ...17 2.4.3 數值方法………..………. ...19 2.4.4 國內外對於模流軟體發展的狀況……..…
… ...20 第三章 實驗方法與步驟.………... 32 3.1 實驗設備與材料………
…...….. ...32 3.2 實驗方法………...…….. ...32 3.2.1 模型的建立………...…………
… ...32 3.2.2 模擬之設計參數………...…… ...33 3.2.3 凝固模擬過程………...…………
...34 3.3 實際澆鑄驗證..……….. ...38 第四章 結果與討論………
………... ..54 4.1 使用Iso-Surface plot來判斷縮孔………...… ...54 4.2 煞車碟盤之凝固模擬………
…... ...58 4.2.1 無設置冒口和冷鐵的碟盤鑄件………... 58 4.2.2 利用密度函數準則分析冒口對凝固之影響
…... 59 4.2.3 利用密度函數準則分析冷鐵對凝固之影響…... 61 4.3 煞車碟盤之流動模擬………...………
………... ..64 4.3.1 非壓力式澆口比之流動解析……….……….. ...64 4.3.2 壓力式澆口比之流動解析……….…
…….. ...66 4.4 煞車碟盤之冒口最佳化………... ...67 第五章 結論………
………... .105 參考文獻………... 107
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