Basic research on super-high-vacuum semisolid high-pressure-die casting

超高真空半固态高压压铸基础研究

• 批准号: 17560654
• 负责人: OHNAKA Itsuo
• 金额: $ 2.24万
• 依托单位: Osaka Sangyo University, Graduate School of Engineering
• 依托单位国家: 日本
• 项目类别: Grant-in-Aid for Scientific Research (C)
• 财政年份: 2005
• 资助国家: 日本
• 起止时间: 2005 至 2006
• 项目状态: 已结题
• 来源: https://kaken.nii.ac.jp/en/grant/KAKENHI-PROJECT-17560654/
• 关键词: Metal manufacturing engineering; Materials processing ＆ treatment; Simulation engineering; High-pressure-die casting; mold filling

The use of light alloys such as Al- and Mg alloys has been increasing to prevent global warming and save energy, and development of high-pressure-die casting (HPDC) with high productivity is required, because weldability of these alloys is bad. However, it is not easy to produce reliable products with the conventional HPDC. We have done a fundamental work to develop super-high-vacuum HPDC as a new process, and the following results have been obtained ;(1) It was confirmed to be able to reduce the cavity till 7kPa for graphite mold and 3kPa for metallic mold with using the proposed gate seal. Although this value of vacuum is better than conventionally obtained in plants, we could not achieve the target of 1kPa. Increasing the degree of vacuum requires a measure to the air permeability of the graphite mold and improving machining accuracy for metallic mold and mounting.(2) The porosity defects of sample plate castings produced by the vacuum HPDC with the pressure of the cavity of 7kPa were greatly decreased and mechanical properties greatly increased, comparing those produced by air atmosphere HPDC.(3) The surface quality was also greatly improved when cast under the vacuum.(4) Direct observation of mold filling with using graphite mold and X-ray has been succeeded, and the mold fillings under vacuum and air atmosphere were rather similar, while the flow into the cavity at gate was more perpendicular when cast under vacuum.(5) Comparison of observed mold filling with computer simulation revealed that the wetting between the melt and mold is large and a new simulation code considering the effect has been almost developed.(6) It seemed that high quality products can be produced with a new high-vacuum HPDC including the proposed gate seal.

为了防止全球变暖和节约能源，诸如Al和Mg合金的轻合金的使用已经增加，并且需要开发具有高生产率的高压压铸（HPDC），因为这些合金的可焊接性差。然而，用传统的HPDC生产可靠的产品并不容易。我们为开发超高真空HPDC新工艺做了基础性工作，取得了以下成果：（1）证实了采用所提出的浇口密封装置，可使石墨型腔减小到7kPa，金属型腔减小到3kPa。虽然该真空值比工厂中常规获得的真空值更好，但我们无法实现1kPa的目标。提高真空度需要采取措施，以透气的石墨模具和提高加工精度的金属模具和安装。(2)与空气气氛高压脉冲金刚石压铸件相比，采用真空高压脉冲金刚石压铸件，在7kPa的型腔压力下，试样的气孔缺陷明显减少，力学性能明显提高。(3)在真空条件下浇铸，表面质量也得到了很大的改善。(4)用石墨型和X射线直接观察充型过程，发现真空和空气气氛下的充型过程非常相似，而真空铸造时浇口处的流动更加垂直。(5)观察到的充型与计算机模拟的比较表明，熔体和模具之间的润湿是大的，一个新的模拟代码考虑的效果几乎已经开发。(6)看来，高品质的产品可以生产一个新的高真空HPDC包括拟议的浇口密封。

项目成果

鋳造シミュレーションの最近の動向

铸造模拟的最新趋势

• 发表时间: 2006
• 期刊: 鋳造工学 78
• 作者: 大中逸雄;杉山明;安田秀幸;大中逸雄
• 通讯作者: 大中逸雄

Visualization of Phenomena in Mold-Casting-

模具铸造现象的可视化-

• 发表时间: 2007
• 期刊: Journal of Precision Engineering 73
• 作者: I.Ohnaka;A.Sugiyama;T.Ikeda;H.Yasuda;Itsuo Ohnaka
• 通讯作者: Itsuo Ohnaka

Mold Filling and Prevention of Gas Entrapment in High-Pressure Die-casting

高压压铸中的充型和气体滞留的预防

• 发表时间: 2008
• 期刊: J.Mater.Sci.,Technol 24
• 作者: 栗田典明;共著 (山口周監修);I.Ohnaka,A.Sugiyama,T.Ikeda and H.Yasuda
• 通讯作者: I.Ohnaka,A.Sugiyama,T.Ikeda and H.Yasuda

Direct Observation and Numerical Simulation of Mold Filling

模具充型的直接观察与数值模拟

• 发表时间: 2006
• 期刊: Modeling of Casting, Welding and Solidification Processes XI, TMS, (2006.5,Opio, France.)
• 作者: A.Sugiyama;I.Ohnaka;J.Iwane;T.D.Zhu;H.Yasuda
• 通讯作者: H.Yasuda

Direct Observation and Numerical Simulation of Mold Filling,

模具填充的直接观察和数值模拟，

• 发表时间: 2006
• 期刊: Modeling of Casting, Welding and Solidification Processes XI, TMS, (2006. 5, Opio, France.),
• 作者: A.Sugiyama;ほか
• 通讯作者: ほか