Abstract
Taking an aluminum alloy gearbox of an automobile as an example, according to its structural characteristics, the parting surface was determined, and the initial gating system was designed by using 3D modeling software UG. Based on Magmasoft software, the numerical simulation of the filling and solidification process was carried out to determine the best gating system scheme. The cooling system and core pulling structure were designed, and the parameter design process of the aluminum alloy gearbox shell in the die-casting process was introduced. Aiming at the leakage problem of the gearbox shell in the bench and road test after assembly, the cause was found through numerical simulation and industrial CT analysis, and the problem was solved by adding high-pressure point cooling at the corresponding position of the leakage, and the correctness of the optimization was verified. It provides an effective method for the die-casting production of the transmission housing and the analysis and solution of product defects, which improves the product quality and shortens the production cycle.
Highlights
The internal quality of the gearbox shell is required to be high in strength, air tightness and lightweight [1]
Most of the aluminum alloy gearbox is used in the industry
The automobile gearbox is generally made of aluminum alloy by die-casting and processed by mechanical processes
Summary
Taking the aluminum alloy gearbox housing of an automobile as an example, as shown in Figure 1, the product structure is very complex, and the surface is covered with concave and convex structures such as oil pipeline, reinforcing bars and installation holes, so the mold has a side core-pulling mechanism. Taking the aluminum alloy gearbox housing of an automobile as an example, as shown, the product structure is very complex, and the surface is covered with concave and convex structures such as oil pipeline, reinforcing bars and installation holes, so the mold has a side core-pulling mechanism. The chemical composition and mechanical properties of the material are shown in Table 1 [4,5]. The shrinkage of the casting is required to be 6‰. The castings have high-density requirements, more oil passage holes, strict leak detection requirements and high porosity requirements. The cross-sample requirements are that the porosity is not higher than 5%, and the pore size is not higher than 3 mm. It is difficult to achieve sequential solidification in the later solidification, and it is difficult to die cast
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