机电工程技术2025，Vol.54Issue(9)：55-60,6.DOI:10.3969/j.issn.1009-9492.2025.09.012
基于材料-结构-工艺一体化的一体式前机舱薄壁压铸件开发
Development of Integrated Thin-walled Die-casting Parts for Front Cabin Based on Material-Structure-Process Integration
摘要
Abstract
Material-structure-process integration for the integrated front cabin structure is studied,focusing on the process feasibility design,process simulation analysis,and process optimization methods.Firstly,the integrated front cabin structure is designed using topology optimization methods,achieving a balance between mechanical performance and process feasibility under multi-condition constraints.Secondly,numerical simulation is used to analyze the filling process of the original gate design(4 200 mm²),revealing a filling time of 146 ms,which deviates from the theoretical value by 38.9%,primarily due to gate timing asynchrony and uneven velocity field distribution.To address these issues,the inner gate cross-sectional area is optimized to 5 080 mm²(an increase of 21%),reducing the filling time to 89.3 ms and improving filling efficiency by 38.8%,meeting process requirements.After optimization,the melt flow rate is increased by 21%,the temperature field distribution at the end becomes more uniform,and the monitoring point temperatures are significantly increased,with a maximum temperature rise of 12℃,effectively reducing the risk of cold shut defects.The research results demonstrate that the integrated material-structure-process analysis method significantly enhances process stability,providing theoretical support for the application of aluminum alloy integrated die-casting technology in high-integration vehicle body manufacturing.关键词
一体式前机舱/材料-结构-工艺一体化/压铸工艺仿真/工艺优化Key words
integrated front cabin/material-structure-process integration/die-casting process simulation/process optimization分类
交通工程引用本文复制引用
孟宪明,曹兴枫,任鹏飞,张赛,赵庆..基于材料-结构-工艺一体化的一体式前机舱薄壁压铸件开发[J].机电工程技术,2025,54(9):55-60,6.基金项目
天津市科技计划项目(24ZXZSSS00580) （24ZXZSSS00580）
中国汽车工程学会青年人才托举工程项目(QK-20240316-011) （QK-20240316-011）
中国汽车技术研究中心有限公司科研项目(ZX23240003) （ZX23240003）
