Improving Process Reliability of Cast-in Insertion Bonding by CAE Application

通过 CAE 应用提高铸嵌插入焊接的工艺可靠性

• 批准号: 15560638
• 负责人: NOGUCHI Toru
• 金额: $ 2.05万
• 依托单位: Hokkaido University
• 依托单位国家: 日本
• 项目类别: Grant-in-Aid for Scientific Research (C)
• 财政年份: 2003
• 资助国家: 日本
• 起止时间: 2003 至 2004
• 项目状态: 已结题
• 来源: https://kaken.nii.ac.jp/en/grant/KAKENHI-PROJECT-15560638/
• 关键词: Casting; Bonding; Cast iron; Solidification simulation; Flow simulation; Cast-in insertion; Gating system; Fatigue properties; 異種材料接合; 鋳ぐるみ; 湯流れ; CAE

(1)Commercial flow and solidification simulation system was applied to improve the bonding states and the process reliability of cast-in insertion, and combined with the author's bonding theory, the method of determining the optimal casting and gating system was established.(2)For the two types of insertion, buried insertion and end face bonding of steel inserts in cast iron, basic ideas to optimize the gating system was clarified.(3)The ideas were verified by the experiments. Enhancing effect of Ni alloy plating on the bonding was also examined.(4)The method was successfully adopted to the actual production line of ductile iron castings for automobile use bonded with carbon steel insertions.(5)Fatigue tests were carried out on test pieces from the bonded samples. It was verified that when the test section cleared the UT inspection and boundary diffusion progressed enough, the bonded junctions have good fatigue properties. When the diffusion is not enough, possibility of low fatigue strength was pointed out because of the plated layer acting as fatigue origin.

（1）应用商用流动与凝固模拟系统改善镶铸件的结合状态，提高镶铸工艺的可靠性，并结合作者的结合理论，建立了确定最佳浇注系统的方法。（2）针对铸铁件镶钢件的埋镶和端面粘结两种类型，阐明了优化浇注系统的基本思路。（3）通过实验验证了本文的观点。研究了镍合金镀层对键合的增强作用。（4）将该方法成功地应用于汽车用球铁件碳钢镶块粘结的实际生产线。（5）对来自粘结样品的试样进行疲劳试验。结果表明，当测试段通过超声波检测且边界扩散足够时，键合接头具有良好的疲劳性能。当扩散不足时，由于镀层起疲劳源的作用，疲劳强度可能降低。

项目成果

長手宏和, 堀川紀孝, 野口徹: "市販の湯流れ凝固シミュレーションの複合化鋳造への応用"日本鋳造工学会第143回全国講演大会講演概要集. 48 (2003)

Hirokazu Nagate、Noritaka Horikawa、Toru Noguchi：“商用熔体流动凝固模拟在复合铸造中的应用”日本铸造工程学会第 143 届全国会议摘要 48 (2003)。

Size Effect in Cast-in Insertion Process

铸嵌插入过程中的尺寸效应

• 发表时间: 2004
• 期刊: International Journal of Cast Metals Research 16-1/3
• 作者: Noritaka Horikawa;Takashi Ito;Toru Noguchi;Takashi Nakamura
• 通讯作者: Takashi Nakamura

Application of Flow and Solidification Simulation in Cast-in Insertion Process

流动和凝固模拟在铸镶过程中的应用

• 发表时间: 2005
• 期刊: International Journal of Cast Metals Research (In print)
• 作者: Toru Noguchi;Noritaka Horikawa;Hirokazu Nagate;Hirokazu Sato
• 通讯作者: Hirokazu Sato

Application of Flow, Solidification Simulation in Cast-in Insertion Process

流动、凝固模拟在铸镶过程中的应用

• 发表时间: 2005
• 期刊: International Journal of Cast Metals Research Vol.18 (in print)
• 作者: Toru Noguchi;Noritaka Horikawa;Hirokazu Nagate;Hirokazu Sato
• 通讯作者: Hirokazu Sato

大型トラック強度部材の溶接-鋳造同時拡散接合による大型トラック用アクスルハウジングのFCD化-

重型卡车强度件的焊接-通过同时铸造和扩散结合对重型卡车桥壳进行FCD转换-

• 发表时间: 2004
• 期刊: 溶接技術(日本溶接協会誌) 52-11
• 作者: 黒木俊昭;佐藤一広;野口 徹
• 通讯作者: 野口 徹