Optimization of Tilt-Casting of Aluminum Alloy Automobile Drain Pipes through Numerical Simulation

The effect of major parameters, such as pouring temperature, tilt time and preheating temperature of mold, on the tilt casting of aluminum alloy automobile drain pipes is studied through numerical simulation using single factor and orthogonal test methods. The simulation results of single factor test indicate that the increase in the pouring temperature and mold preheating temperature could effectively reduce the shrinkage tendency and the shortage of tilt time would cause lower temperature gradient of casting at the beginning of solidification, thus would lead the extension of solidification time. And the results of orthogonal test showed that the sequence of factors having effect on the filling and solidification process, are pouring temperature, tilt time and preheating temperature of mold. Finally, combined the result of single factor test with orthogonal test, an optimized tilt-casting process was proposed by investigating the velocity distribution at each stage of the filling process and the isolated area distribution of liquid phase in the solidification process, and by predicting the position of porosity in the casting. The effectiveness of the proposed process parameters in producing high quality castings is also proved through numerical simulation.