Magmasoft軟件高壓鑄造(HPDC)課件

壓鑄模擬課件李高峰GeometryModelingModeltheoverflowsandthecastingasmaterialgroup1('CastAlloy').Ifmodeledasmaterialgroup'Gating'or'Ingate',thecalculationoftheshotprofilewillbedoneincorrectly.overflow溢流包Totalvolumeof'Inlet'and'Biscuit'shouldbeequaltovolumeofthebiscuitofactualcasting.Thisensuresthatthethermalhistoryofdieintheregionofbiscuitiscorrectlymodeled.Ifcombined'Inlet'plus'Biscuit'volumeisbiggerthanthevolumeofshotsleeveattheendofthefirstshotphase(i.e.shotsleeveis100%filled),fillingsimulationwillnotstart.Theenmeshmentof'Inlet'and'Biscuit'shouldresultinaminimumof2layersofelementsalongthelengthof'Inlet'and3layersalongthelengthof'Biscuit'.GeometrymodelingIfHPDCcalculatorisusedfordeterminingapouringrate(shotcurve),thevolumeof'Biscuit'mustcorrespondtothebiscuit(whichisthewholebiscuit)minusthe'Inlet'volumeGeometrymodelingGeometrymodeling21Movabledie(Sidecore/'SIDEC')22Movabledie(Ejectordie/'EJECTOR')23Fixeddie(Coverdie/'COVER')25Biscuit(withoutInlet)('BISCUIT')32Squeezestamp('STAMP')33Squeezereservoir('RESVR')Thepistonismodelledwithmaterialgroup23.Use'localsqueezing'functiontosimulatelocalsqueezingviameltreservoirs.Definethestartingtime(calculatedfromtheendoffilling),thedurationandthepressure.Thesqueezingprocessisterminatedwhenthedieisopenedforthefirsttime.SimulationsetupUse'MERGEMATERIALS'todefineanidealheattransferbetweentwovolumes,whichhavethesamematerialgroupbutdifferentMATIDsandwhicharenotphysicallyseparatedinreality,butforwhichyouwanttosimulatedifferentboundaryconditions.ByusingHPDCcalculatoryoumustdefineaflowrateformoldfilling.UsethelastwindowofHPDCcalculatortosimulateventingofthedie.Definetheopeningofdiepartsvia'coreopendefinitions'.Definethecontrolofcoolingchannelsvia'channeldefinitions'.Forfillingsimulation,threeoptionsareavailableunder'fillingdefinitions'/'fillingdependson'.AshighflowvelocitiesoccurinHPDC,youshouldalwaysviewthemolderosioncriterion.Activate'calculateerosion'/'yes'.SimulatediecoolingbyapplyingapartingcompoundondiesurfacewithMAGMAcoatoption.SimulatediecoolingbysprayingandblowingwithMAGMAsprayoption.Simulate'solidificationdefinitions'/'localsqueezing'.YoumustcalculatepressurizedsolidificationwiththeMAGMApressurizeoption.HPDCMachineParametersintheDatabaseMax.pistonacceleration:m/s2.Wehighlyrecommendtoadaptthevalueformaximumpistonaccelerationtotheconditionsinyourfoundry.Define'Max.pistonacceleration'usingrecordedpouringcurves.α=MaximumpistonaccelerationΔv=Velocitydifferenceofphase2-phase1Δt=Timedifferencebetweenendofacceleration(phase2)minusbeginofacceleration(phase1)Inputofhydraulicparameters:Max.injection(hydraulic)pressure:Maximuminjectionpressure(piston-typeaccumulator)(bar)DiameterofhydrauliccylinderMax.dynamicinjectionforce(kN)Max.multiinjectionforce:Relationoftranslation,multipliedwiththisforce(kN)=maximumfinalpressureHpdcdatasetinMagmaWerecommendtouseademomachineifyouwanttocreatedatasetstoyourneeds.Thedatainthe'MAGMA'databasecannotbeusedimmediately,butmustbeimportedtoatleastoneofthe'User','Global'or'Project'databasesandmaybecorrectedthere.

'Readytouse'functionisdeactivatedinalldatasetsof'MAGMA'database.CalculatingaShotProfile/'HPDCcalculator'biscuit:themeltvolumethatstaysandsolidifiesintheshotchamberafterplungermovement(plungerendposition).Beconsistsofvolumes'Biscuit'and'Inlet'.runners:volumeofrunningandgatingsystemissumofvolumes'Gating'and'ingate'.moltenmetalladled:sumof'biscuit','runners'and'cavity+overflow'GeometrydataIngatearea:crosssectionarea.Dependingonthespatialpositionoftheingate,calculationofcrosssectionareafromgeometrydatamaybeinaccurate.Iftheingatecrosssectionisparalleltothecoordinatesystem,theareaiscalculatedaccurately.Thisvaluealwayshastobecheckedandreplacedbyactualvalueifnecessary.Projectedarea:projectedcastingareaindiepartingplane.Asdefault,theprojectedareasareactivetowardsinlet.Projectedareasforpossiblesidecores/slidersarenottakenintoaccount.Youmustcorrectthemmanually.characteristicwallthicknessofthecasting:Thisvalueisnottakenfrompreprocessordatabuthastobedefinedbyyou.qualityrequirement:'standard','technical'or'high'.Thequalityrequirementservesselectionofthespecificfinalpressure('requiredspecificpressure').Machinedatarequiredspecificpressure:dependsonthealloyandqualityrequirementforthecasting.Youhavetodefinethequalityinthewindow'geometrydata'at'quality'.selectedspecificpressure:Validvaluesliewithintheintervalof'requiredspecificpressure'.Thevaluedefinedhereisusedasdefaultforthe'workingpressure'valuewithinMAGMApressurizeoption.min.requiredclosingforce:Productvalueof'projectedarea'and'selectedspecificpressure'.Itisonlyvalidforadiewithoutsidecores.Ifusedieswithsidecores,itcanbemuchhigherduetoadditionallockingforcesofsidecores!Youshouldcarryoutthecalculationofeffectiveprojectedareaofsidecores.Youmustaddthedeterminedadditionalareainthefield'projectedarea'ofthewindow'geometrydata'.Specificcastingpressures[bar]AluminiumZincMagnesiumBrassStandard200-400100-200200-400300-400Technical400-600200-300400-600400-500Pressure-tight800-1000250-400800-1000800-1000Definingshotsleevedatadiameterofplunger:correspondstothebiscuitdiameter.shotsleevefilling:fillingdegreeinpercent.Itcannotbeedited,beautomaticallycalculatedfromthelengthofshotsleeveandplungerdiameter.volumeofshotsleeve:Volumeofshotsleeveuptoplungerendpositionacceleratedfirstphase:on:MAGMAhpdccalculatesanacceleratedshotprofile('fillingphase',MoldFilling).Inthiscase,thebutton'opt.slowshot'isdeactivated.off:MAGMAhpdccalculatesanon-acceleratedshotprofile.opt.slowshot:OptimizationoftheshotprofileforcoldchamberHPDCmachinesinthefirst(slow)phase.shotprofile:toinvokeagraphofthecalculatedshotprofile.Curveofpouringrateandtime.PQ2:Apictureisinvokedthatshowsthemeltflowsituationforliquidmetalwithinthecastingsystemuptotherunnersandgating.ItshowsconnectionbetweenmetalpressurePandmetalvolumeflowQ,orpistonvelocity,dependentonthegating'scrosssectionanddensityofthealloy.showsthemeltflowsituationfortheliquidmetalwithinthecastingsystemuptotherunnersandgatingmetalpressureP(bar)metalvolumeflowQpistonvelocity(m/s)dependentonthegating'scrosssectionanddensityofthealloyslowshotvelocity:Velocityoftheplungerduringthefirstphase,vI=constant.Iftheoptions'acceleratedfirstphase'or'opt.slowshot...'areactive,themaximumvelocityduringthefirstphaseisshown.theoreticalcavityfillingtime:forfillingfromingate.Thisvalueiscalculatedfrom'characteristicwallthickness'valueandthealloy.Processdatafastshotvelocity:velocityoftheplungerduringthesecondphase,vII=constantcavityfillingtime:fillingtimethatiscalculatedagainincaseparametershavebeenchangedStandardvaluesforfillingWallthickness[mm]Fillingtime[ms]1,510-301,820-402,020-602,330-702,540-903,050-1003,850-1205,060-2006,480-300Shotcharacteristicsswitchoverstage1-2:Startofaccelerationphase(switchingpoint).單位：mmUptothisplungerposition,thedieisfilledwithvelocityofthefirstphase('slowshotvelocity').Iftheplungerintheshotchamberhasreachedthisposition,itisaccelerateduptovelocityofthesecondphase('fastshotvelocity').plunger,startofstage2：Positionofplungerifthesecondphaseisreachedplunger,runnerfullposition：Positionofplungeriftherunningsystemisfilled(metalatingate)slowshotvelocity：Velocityofplungerinthefirstphase,vI=constantfastshotvelocity：Velocityofplungerinthesecondphase,vII=constantcavityfillingtime：Fillingtime,countedfromingateoptimalingatearea：Optimalcrosssectionareaofingate,proposedbytheHPDCcalculator.Thecrosssectionareaiscalculatedbasedonthedata.Itdoesnotnecessarilyreflecttherealarea.velocityattheingate:VelocityofthemeltifitenterstheingateForthevalues'displayof'cavityfillingtime'and'velocityattheingate',pleasenote:Ifdefinetoohighvelocitiesandtoolongtimes,thesearehightlightedred.Ifyoudefinetooslowvelocitiesandtooshorttimes,thesearehighlightedblue.VentingOptionsFillingdefinitionsHPDCcalculatedflowrate:PouringratecalculatedintheHPDCcalculatorisshowninthiswindow.Notethatpouringratearenotabletomodify.HPDCuser1flowrate:ReachawindowthatshowsthepouringratecalculatedintheHPDCcalculator.Youcaneditthepouringrate.HPDCuser2flowrate:IftheHPDCcalculatornotused('skip'inthewindow'highpressurediecasting'),youcanmanuallyeditapouringratehere.ThiscanbeusefulforexampletoenterdatadirectlymeasuredatyourHPDCmachine.Pleasetakecarenottochoose'pressure'here.ThereisavitaldifferencebetweenpouringrateswithandwithoutHPDCmodule.IfHPDCmoduleisnotactive,meltflowstartsat0.0seconds.Theinletisfilledfirst,thenthegatingsystemandingate.Thetime0.0co