摘要
高速铁路用ZL114A铝合金棘轮存在质量大、缺陷多等问题。为了获得高品质、轻量化的棘轮,对现有棘轮进行结构和铸造工艺研究。采用无损检测方法获得了棘轮存在缺陷的位置,运用铸造模拟软件ProCAST对棘轮低压铸造的充型和凝固过程进行仿真,预测了棘轮中可能出现缩孔、缩松的位置。通过在棘轮的轮辐和大轮位置处添加水冷系统,以及提高保压压力,对铸造工艺进行改善。受力分析和模流分析结果表明:新设计的棘轮质量减小18.8%,棘轮在工作载荷和破坏载荷下受力安全,满足使用要求;铸造工艺改善后,充型平稳,没有出现紊流现象,金属液表现为顺序凝固,有效避免了缩孔、缩松、氧化渣等缺陷,可以获得高品质的棘轮铸件。
The ratchet wheel made of ZL114A aluminum alloy in high-speed railway has many problems such as heavy weight and numerous defects.In order to obtain high-quality and lightweight ratchet products,the structure and casting technology of the existing ratchet were studied.The defective position of the ratchet wheel was obtained by nondestructive testing.The filling and solidification process of the ratchet wheel in low-pressure casting were simulated by the software ProCAST,and the location of possible shrinkage cavity and porosity in the ratchet wheel was predicted.The casting process was improved by adding a water cooling system at the spoke and large wheel positions of the ratchet and increasing the pressure pressure.The results of force analysis and flow analysis show that,the weight loss ratio of the optimized ratchet reaches 18.8%.The ratchet is safe under working load and damage load,its safety factor meets the requirements of safe use.After improving the casting technology of the ratchet wheel,the filling is stable without turbulence phenomenon,and the molten metal shows sequential solidification,which effectively avoids the defects such as shrinkage cavity,porosity,and oxidation slag,and,high-quality ratchet castings can be obtained.
作者
高睿恒
李贞
王雪强
包有宇
彭立明
王迎新
GAO Ruiheng;LI Zhen;WANG Xueqiang;BAO Youyu;PENG Liming;WANG Yingxin(Power China Chengdu Electric Power Fittings Co.,Ltd.,Chengdu 610100,China;School of Naval Architecture,Ocean and Civil Engineering,Shanghai Jiao Tong University,Shanghai 200240,China;Shanghai Light Alloys Net Forming National Engineering Research Center Co.,Ltd.,Shanghai 201600,China;National Engineering Research Center for Precision Molding of Light Alloy,School of Materials Science and Engineering,Shanghai Jiao Tong University,Shanghai 200240,China;Sichuan Research Institute,Shanghai Jiao Tong University,Chengdu 610100,China)
出处
《热加工工艺》
北大核心
2023年第21期128-132,136,共6页
Hot Working Technology
基金
国家自然科学基金项目(U2102212)。
关键词
高速铁路
低压铸造
棘轮
铸造工艺
轻量化设计
high-speed railway
low pressure casting
ratchet
casting process
lightweight design
