Study on casting design and analysis of magnesium alloy wheel

PurposeThis research establishes a suitable casting model for magnesium alloy wheel. The casting of the wheel is an element that must be considered in the design of the wheel. Casting is an important basic process and technology in the field of machinery which is widely used in production, transportation, national defense, social life and other aspects. Computer numerical simulation of the casting process can shorten the product manufacturing cycle, reduce product costs, reduce casting defects and ensure product quality. The casting material in this study is AZ91 magnesium alloy used for wheel lightweight.Design/methodology/approachLightweight research of automobile is a significant trend, and people are paying attention to the lightweight design of automobiles. Higher requirement was proposed on design and casting performance of the wheel which is an important part of lightweighting vehicle. In order to achieve better quality, the parametric studies of alloy wheel and casting are necessary. This research designs a new model of automobile wheel, to ensure energy efficiency, the wheels must be as lightweight as possible, using magnesium alloy material for lightweight.FindingsAnalysis of casting process is a very complex issue. This research based on finite element theory and actual production, designed reasonable casting model, instant filling and solidification data were obtained. Aiming at reducing casting defects, process improvement of casting riser structure was designed. On the basis of the foundation, it has important guiding significance for actual foundry production.Originality/valueThis research establish a suitable casting model for magnesium alloy wheel. Aiming at reducing casting defects, process improvement of casting riser structure were designed.

Optimization of a gating system by means of simulation software to eliminate cold shut defects in casting

The current trend in foundries is to achieve the production of high quality and competitive cast components. The innovation and optimization of current processes is a necessary element to achieve this goal. With the help of numerical simulations, it is possible to replace financially demanding and time-consuming experiments in real conditions with simulations that can reliably represent foundry process using computer technology. By a detailed analysis of the simulation results, we can predict various risks that could negatively affect the production process. This article monitors the influence of changes in the design of the gating system on the surface quality of a clutch wheel casting made of ductile iron, in the production of which two models of the gating system for casting were constructed in CAD software. Verification of gating systems was performed using the simulation software NovaFlow & Solid. The aim of the design change of the gating system is to reduce the amount of liquid metal used per casting, which can have a significant economic impact on industrial production. For this purpose, several simulations of the gating system of the casting were performed, while 2 which are the most representative for the mentioned problem were selected for the needs of the article. The main task of the simulation was to set the cellular network and conditions as close as possible to the reality of casting and the subsequent design and modification of the gating system.

DEVELOPMENT OF HEAT-INSULATING COATINGS FOR DIE MOULD OF LOW-PRESSURE CASTING

Influence of heat-insulating release coatings on quality of light-alloy wheels is considered. Comparison of properties of the developed compositions and foreign analogues is carried out. Computer simulation of wheel casting by low pressure method in the painted die mould is executed. Results of approbation of the developed composition under the conditions of existing industry are presented.