Abstract
In this paper, aiming at focusses on many problems existing in the mathematical model of temperature change in the low-pressure casting solidification process of aluminum alloy wheel hub, there is a big gap between the simulation and the actual temperature change, which affects the research on the solidification defects of the wheel hub. In order to study the solidification behavior of aluminum alloy hub in low-pressure casting process, the mathematical model describing the temperature change in the process of casting solidification is established by using different solidification latent heat methods. through finite element simulation and experiment, the temperature change in the process of aluminum alloy (A356) solidification is obtained to compare the difference between the temperature change described by different mathematical models, simulation and experiment. The results show that the temperature numerical model of "the temperature compensation heat capacity method" proposed in this paper is most consistent with the simulation temperature change during the solidification process of the aluminum alloy wheel in the simulation mold, which lays a good theoretical foundation for the study of the low-pressure casting process of the aluminum alloy wheel hub.
Highlights
At present, due to the advantages of high rigidity, low density, and good workability of aluminum alloy materials [1], the weight reduction, high strength-to-weight ratio, and good mechanical properties of aluminum alloy wheels have been achieved, which has increased the Automotive applications [2].These aluminum alloy wheels are usually cast using a low-pressure die-casting process
There is a big error between the temperature change of ProCAST simulation and the real result, especially when the aluminum alloy liquid changes from solid-liquid phase to solid phase, the maximum error is up to 40 ◦ C, which shows that the simulation itself has a big disadvantage, which may be the error between the solidification simulation process and the real one, or the simulation magnifies the influence of latent heat, especially when the solid-liquid phase changes to solid phase
By comparing the results of different numerical methods, finite element simulation with the results of experiment, it is found that the "the temperature compensation heat capacity method" has higher accuracy than other numerical methods
Summary
Due to the advantages of high rigidity, low density, and good workability of aluminum alloy materials [1], the weight reduction, high strength-to-weight ratio, and good mechanical properties of aluminum alloy wheels have been achieved, which has increased the Automotive applications [2]. Low-pressure cast aluminum alloy wheels have the advantages of high production efficiency, low cost, and good mechanical properties. Today, this preparation method has gradually become the main method of wheel manufacturing [3]. In order to improve the accuracy of the numerical simulation of the wheel solidification process, it is of great significance to establish an accurate latent heat model. For the narrow time step of the solid-liquid region, the equivalent heat capacity method is generally used to improve the accuracy of temperature simulation. Numerical simulation and theory are combined to study the latent heat numerical model of the solidification process in the low-pressure casting of aluminum alloy wheels. The finite element model is used to simulate the temperature change at a certain point of the wheel hub and the result of this method is compared to verify the accuracy of the method
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