外文翻譯----cadcaecam集成系統(tǒng)在壓鑄模具中的應(yīng)用-模具設(shè)計(jì)(文件)
【正文】 擬及分析 壓鑄件油泵的生產(chǎn)使用的是 IP 550 臥式壓鑄機(jī)。在數(shù)據(jù)庫 I 中存儲了各種標(biāo)準(zhǔn)零部件的數(shù)據(jù)和模具設(shè)計(jì)的經(jīng)驗(yàn)數(shù)據(jù)，如鑲嵌的厚度，型腔內(nèi)表面到模具外表面的距離等一些經(jīng)驗(yàn)數(shù)據(jù)，隨著該專業(yè)軟件系統(tǒng)數(shù)據(jù)庫 I 的使用，該壓鑄模完整的三維實(shí)體造型終于全部完成，包括外表面和噴射機(jī)構(gòu)，型芯，澆注系統(tǒng)，溢出和冷卻通道等（如圖 3 所示） 。鑄件的加工余量，收縮率和錐度大小的數(shù)據(jù)是根據(jù)零件的表面精度等級、零件的結(jié)構(gòu)和合金類型從數(shù)據(jù)庫 II 中選擇。然后用 CAE 模擬軟件模擬壓鑄過程中金屬液在模具中的流動(dòng)和凝固過程。 由于壓鑄件形狀復(fù)雜，需要大型的 CAD/CAM軟件的三維實(shí)體造型和制造。交貨的時(shí)間和整體的設(shè) 計(jì)與制造周期可以大大縮短 [2]。第二步是設(shè)計(jì)壓鑄工藝中的澆注系統(tǒng)，溢出和冷卻通道，以及壓鑄模具的整體框架。壓鑄件的結(jié)構(gòu)正變得越來越復(fù)雜化和大型化，同時(shí)，一個(gè)新的壓鑄產(chǎn)品的開發(fā)周期要求更短。這種集成系統(tǒng)已成功應(yīng)用于鋁、鎂壓鑄件 的模具設(shè)計(jì)和制造，如桑塔納汽車的油泵。 Numerical simulation of metal flow and solidification 1. Introduction The application of die castings is expanding continuously. The construction of die castings is being more plex and largesized, and at the same time a shorter development cycle of new die casting products is required. How to produce high quality die castings in a shorter period with a lower cost has bee an important and urgent task of die casting enterprises. Recently concurrent engineering (CE) has been introduced into die casting production, and the CAD/CAE/CAM integrated system of die casting dies has been established [1]. In the CE process, the first step is to create a 3D part database for use in all aspects of the production process. The next step is to design the die casting process, which includes the design of gating system, overflows and cooling channels and whole set of die casting dies. In order to avoid the defects in the casting, by means of the casting simulation software the numerical simulation of metal flow and solidification in the dies, . the CAE, is performed. The database also provides the data which are needed in the generation of the cavity roughing and finishing CNC programs for die manufacturing by CAM, and is connected to the coordinate measuring machines (CMMs) for measuring [1,2]. Due to the use of a unitary database of 3D model in the whole period, all these steps can be performed simultaneously. The leadtime and whole cycle of design and manufacture can be shortened greatly [2]. Therefore, die casters have paid more and more attention to the CAD/CAE/CAM integrated system of dies, which embodies the CE concepts of modern advanced manufacturing technique. 2. Establishment of the CAD/CAE/CAM integrated system for die casting dies The general scheme of CAD/CAE/CAM integrated system of die casting dies is shown as Fig. 1. A CAD/CAM software, a CAE simulation software and a die casting expert system are included in it. Due to the plex shape of die castings, the largescale CAD/CAM software is required for the 3D solid modeling and manufacturing. Now the widely used CAD/CAM software are Pro/ENGINEER CAD/CAM software of PTC, Unigraphics II CAD/CAM software of EDS, and IDEAS CAD/CAM software of SDRC, USA. The principle of CAE simulation of castings is based on the solving of the equations in fluid dynamics and heat transfer (such as the continuity equation, the Navier–Stokes equation and the Fourier equation, etc.) by means of finite difference method (FDM) or finite element method (FEM). The velocity profile of the metal flow in the die cavity and the temperature distribution of the casting and die during the filling and solidification process can be obtained by calculation. Then the metal flow and solidification of die castings are simulated with the use of CAE simulation software. The
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