外文翻譯----cadcaecam集成系統(tǒng)在壓鑄模具中的應用

1、<p>　　附 錄A 外文文獻及譯文</p><p>　　Application of an integrated CAD/CAE/CAM system for die casting dies</p><p><b>　　Abstract</b></p><p>　　According to the concept of concu

2、rrent engineering (CE), a CAD/CAE/CAM integrated system for die casting dies is established and applied in the primary stage. The platform of the Pro/ENGINEER CAD/CAM software, the MAGMASOFT simulation software and a pri

3、mary expert system for the design of the die casting process are available to establish this integrated system. A primary expert system package including a series of empirical calculation equations and data for the desig

4、n of technological scheme a</p><p>　　Keywords: CAD/CAE/CAM integrated system; Die casting dies; Numerical simulation of metal flow and solidification</p><p>　　1. Introduction</p><p>

5、;　　The application of die castings is expanding continuously. The construction of die castings is becoming more complex and large-sized, and at the same time a shorter development cycle of new die casting products is req

6、uired. How to produce high quality die castings in a shorter period with a lower cost has become an important and urgent task of die casting enterprises. Recently concurrent engineering (CE) has been introduced into die

7、casting production, and the CAD/CAE/CAM integrated system of di</p><p>　　2. Establishment of the CAD/CAE/CAM integrated system for die casting dies</p><p>　　The general scheme of CAD/CAE/CAM int

8、egrated 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.</p><p>　　Due to the complex shape of die castings, the

9、 large-scale 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/

10、CAM software of SDRC, USA.</p><p>　　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–Stoke

11、s 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 casti

12、ng and die during the filling and solidification process can be obtained by calculation. Then the metal flow </p><p>　　In this paper the platform of the Pro/ENGINEER CAD/CAM software, the MAGMASOFT simulatio

13、n software, and a primary expert system for the design of die casting process are used to establish the CAD/CAE/CAM integrated system of die casting dies, this system is applied for the die castings of a water pump of al

14、uminum alloy and a housing cover of magnesium alloy [4,5].</p><p>　　3. Application of the CAD/CAE/CAM integrated system for die casting dies</p><p>　　3.1. CAD modeling and design of technologica

15、l scheme and dies</p><p>　　First the 3D solid modeling of a part is created, then the 3D modeling of the die casting including the information of machining allowance, shrinkage and taper is formed by using t

16、he Pro/ENGINEER CAD/CAM software (shown as Fig. 2). The data of machining allowance, shrinkage and taper are chosen from Database II in accordance with the accuracy and surface rating of the parts, the structure of the p

17、arts and the type of alloy.</p><p>　　By means of a primary expert system package for the design of the technological scheme of die casting process, which was developed by the authors, the process parameters

18、of die casting such as the injection pressure, plunger speed, gate velocity and filling time, etc. are selected suitably, and checked by empirical calculation equations in accordance with the type of alloy, and the wall

19、thickness and structure of the casting. The technological scheme of die casting process including the gating s</p><p>　　The shape of the die casting of the water pump is comparatively complex. It includes an

20、 involute outline, a groove with varied height, a distorted transition region connecting different transverse sections with a sphere-like arch, etc. All these are difficult for modeling.</p><p>　　3.2. CAE si

21、mulation and analysis</p><p>　　The die casting of water pump is produced in an IP 550 horizontal die casting machine. There are two types of defects occurring in this casting: air holes and porosity. The met

22、al flow and solidification in the dies is simulated with the use of MAGMASOFT software. The simulation results of several technological scheme are analyzed. The problems occurring in the metal flow and solidification can

23、 be observed directly through the simulation. In the original scheme the gating system of the water pump</p><p>　　3.3. The realization of CAM</p><p>　　On the basis of the data of the 3D solid mo

24、deling of the cavities of die casting dies, with the use of the Pro/MANUFACTURING module of the Pro/ENGINEER CAD/CAM software, the 3D solid modeling of blank figures of the inlays are created first. Then the operation ta

25、ble of the machining including the machining parameters, cutters, cutter path, etc. is listed, and the NC (numerical control) cutting procedures and the CL (cutter locate) data files are also created. Furthermore due to

26、the use of the mo</p><p>　　4. Results of the application of integrated system</p><p>　　As mentioned above, with the help of the Pro/ENGINEER CAD/CAM software and a primary expert system package,

27、 the 3D solid modeling of die casting and the design of technological scheme of die casting process are created. Next the simulation and analysis of metal flow and solidification in dies are performed with the use of the

28、 MAGMASOFT software; the technological scheme and process parameters of die casting are also revised and optimized. Then the 3D solid modeling of whole set of dies is comple</p><p>　　The technological scheme

29、 and process parameters of die casting process are revised and further optimized by using the CAE simulation, and the quality of the die castings improved greatly in a shorter time. For example, due to the use of CAE sim

30、ulation, the percentage of qualified products of die castings of the above-mentioned water pump is raised from 60 to 90% in a shorter time.</p><p>　　Another example is a magnesium die casting of a gearbox ho

31、using of a sedan. The CAE simulation results show the unevenness of the temperature distribution in the die cavity. The thermal balance and temperature distribution of the dies are improved with the regulation of process

32、 parameters such as gate velocity, flow rates of cooling media, etc. And the occurrence of cracks is reduced greatly. Because the percentage of qualified products of die castings can be raised greatly in a shorter time,

33、th</p><p>　　5. Conclusions</p><p>　　The established CAD/CAE/CAM integrated system of die casting dies has been used successfully in the design and manufacture of die casting dies of sedan parts

34、such as a water pump, a gearbox housing, etc. The cycle of design and manufacture of die casting dies are shortened obviously. The process parameters and technological scheme of die castings can be optimized with the hel

35、p of CAE simulation. This results in the production of die castings of consistently high quality in a shorter time, and th</p><p>　　References</p><p>　　[1] K. Chipley, S. Viswanathan, R.H. Coop

36、er, Die Cast. Eng. 40 (2)</p><p>　　(1996) 18–26.</p><p>　　[2] P.M. Bralower, Die Cast. Eng. 42 (5) (1998) 16–20.</p><p>　　[3] S.P. Midson, Die Cast. Eng. 38 (5) (1994) 42–46.</

37、p><p>　　[4] S. Yue, G. Dai, Foundry Eng.-Molding Mater. 22 (1–2) (1998) 8–13.</p><p>　　[5] Shuhua, Yue, J. Yu, H. Sun, et al., Foundry 46 (1) (1997) 14–18.</p><p>　　CAD/CAE/CAM集成系統(tǒng)在壓

38、鑄模具中的應用</p><p><b>　　摘 要</b></p><p>　　根據(jù)并行工程（CE認證）的概念，CAD/CAE/CAM集成系統(tǒng)目前已在壓鑄模具設計中得到建立和初級階段的應用。Pro/ENGINEER中的CAD/CAM軟件， MAGMASOFT仿真軟件，和一個可以為壓鑄設計建立壓鑄模具CAD/CAE/CAM集成系統(tǒng)的專業(yè)系統(tǒng)。軟件公司已開發(fā)出一種重要的

39、壓鑄模具專業(yè)軟件系統(tǒng)包，它提供了模具和方案設計中的一系列經(jīng)驗計算公式和數(shù)據(jù)。這種集成系統(tǒng)已成功應用于鋁、鎂壓鑄件的模具設計和制造，如桑塔納汽車的油泵。使用這個集成系統(tǒng)，可以縮短模具設計和制造周期，并在較短的時間里，生產(chǎn)出高質量的壓鑄件。壓鑄件的交貨時間也大大縮短。</p><p>　　關鍵詞：CAD/CAE/CAM集成系統(tǒng)、壓鑄模具、金屬流動和凝固的數(shù)值模擬</p><p><b&g

40、t;　　1、介紹</b></p><p>　　壓鑄件的應用正在不斷擴大。壓鑄件的結構正變得越來越復雜化和大型化，同時，一個新的壓鑄產(chǎn)品的開發(fā)周期要求更短。如何在較短的時期里用較低的成本生產(chǎn)出高質量的壓鑄件已成為壓鑄企業(yè)一項重要而緊迫的任務。最近并行工程（ CE ）已引入壓鑄生產(chǎn)工藝，并且已經(jīng)建立了壓鑄模具CAD/CAE/CAM集成系統(tǒng)[1]。在并行工藝過程中，第一步是創(chuàng)建零件生產(chǎn)過程中所用到的所有方面

41、3D數(shù)據(jù)庫。第二步是設計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。為了避免鑄造中的一些缺陷，可以應用鑄造模擬軟件里的CAE技術對鑄造過程模具中的金屬的流動和凝固進行數(shù)值模擬。該數(shù)據(jù)庫還提供了CAM模具制造過程中CNC程序對腔的粗加工和精加工所需的數(shù)據(jù)，還連接了坐標測量機（CMM）應用于測量[ 1,2]。由于在整個過程中使用的是同一三維模型的數(shù)據(jù)庫，以上這些步驟可以同時進行。交貨的時間和整體的設計與制造周期可以大大縮短

42、[2]。因此，模具設計者對模具的CAD/CAE/CAM集成系統(tǒng)的越來越多的關注，體現(xiàn)了現(xiàn)代先進制造技術的CE技術的重要性越來越大。</p><p>　　2、CAD/CAE/CAM集成系統(tǒng)在壓鑄模具中的建立</p><p>　　CAD/CAE/CAM集成系統(tǒng)壓鑄模具的總體方案如圖1所示。它包括一個CAD/CAM軟件,一個CAE仿真軟件和一個壓鑄專業(yè)軟件系統(tǒng)包。</p><

43、p>　　由于壓鑄件形狀復雜，需要大型的CAD/CAM軟件的三維實體造型和制造?，F(xiàn)在廣泛使用的CAD/CAM軟件是PTC公司的Pro/ENGINEER的CAD/CAM，EDS公司的Unigraphics II的CAD/CAM，和美國IDEAS的CAD/CAM的軟件。</p><p>　　鑄件CAE模擬技術原理的解決方法有：有限差分法（FDM）的流體動力學和傳熱方程（如連續(xù)性方程，Navier-Stokes方程

44、和傅立葉方程等）或有限元法（FEM）。金屬液在模具型腔里的流動速度和鑄件的溫度分布以及金屬液在模具中的填充和凝固過程可以通過計算得出。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和凝固過程。鑄造模擬軟件包現(xiàn)在可用的有EKK的CAP，流體科學的FLOW-3D，美國UES的PRO/CAST，以及德國的MAGMASOFT等[3] 。</p><p>　　本論文使用的是Pro/ENGINEER的CAD/CAM軟

45、件，MAGMASOFT仿真軟件，和一個可以為壓鑄工藝設計建立壓鑄模具CAD/CAE/CAM集成系統(tǒng)的專業(yè)系統(tǒng)，這個系統(tǒng)應用于鋁合金油泵壓鑄件和鎂合金的外殼蓋[4,5]。</p><p>　　3、CAD/CAE/CAM集成系統(tǒng)在壓鑄模具中的應用</p><p>　　3.1、模具的CAD建模和設計的技術方案</p><p>　　首先新建零件的三維實體造型，然后通過使用P

46、ro/ENGINEER的CAD/CAM軟件進行壓鑄件的三維建模，建模的內容有鑄件的加工余量，收縮率和錐度的形成（如圖2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、零件的結構和合金類型從數(shù)據(jù)庫II中選擇。</p><p>　　通過由軟件商開發(fā)的一款重要的專業(yè)軟件系統(tǒng)包進行壓鑄工藝技術方案的設計，可以對壓鑄模的工藝參數(shù)，如注射壓力、柱塞速度、注射速度和充填時間進行適當?shù)倪x擇，根據(jù)合金類型的

47、經(jīng)驗計算公式，可以對壓鑄件的壁厚和結構進行校核。該設計方案還包括澆注系統(tǒng)，溢出和冷卻通道的工藝設計，以及型腔的內表面積和模具的熱平衡的計算和校核。然后選擇壓鑄機。在數(shù)據(jù)庫I中存儲了各種標準零部件的數(shù)據(jù)和模具設計的經(jīng)驗數(shù)據(jù)，如鑲嵌的厚度，型腔內表面到模具外表面的距離等一些經(jīng)驗數(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體造型終于全部完成，包括外表面和噴射機構，型芯，澆注系統(tǒng)，溢出和冷卻通道等（如圖3所示） 。然后把所有模擬

48、數(shù)據(jù)轉換成數(shù)據(jù)文件。</p><p>　　壓鑄件油泵的形狀是比較復雜的。它包括一個漸開線輪廓，具有不同高度的槽，彎曲的過渡區(qū)域連接著不同橫截面的球體狀拱，所有這些都給建模造成很大麻煩。</p><p>　　3.2、CAE模擬及分析</p><p>　　壓鑄件油泵的生產(chǎn)使用的是IP 550臥式壓鑄機。在這個鑄件生產(chǎn)中常出現(xiàn)的缺陷有兩種類型：氣孔和縮孔。該模具中金屬的流

49、動和凝固的模擬使用的是MAGMASOFT軟件。然后對幾種技術方案的模擬結果進行分析。通過模擬可以清楚地看出金屬流動和凝固過程中出現(xiàn)的問題。在充填金屬液的過程中使用傳統(tǒng)的澆注系統(tǒng)進行澆注將會導致金屬液的飛濺和空氣不能及時排出。這將會出現(xiàn)氣孔和氧化夾雜物等缺陷（如圖4所示）。為了減輕這種缺陷，需要對澆注系統(tǒng)的設計進行修改，工藝參數(shù)也要進行相應調整，（如圖5所示）。另外，這種傳統(tǒng)的澆注方案往往會在鑄件的熱節(jié)處出現(xiàn)縮孔缺陷（如圖6所示）。所以，

50、在修改設計方案時，需要控制柱塞的加速度以調節(jié)合適的注射速度，充填的時間也要短，因為充填后的增壓可以使?jié)部谔幬磥淼眉澳痰慕饘僖簩峁?jié)出的縮孔進行補縮。這樣，縮孔缺陷就基本消除了。由于油泵復雜的外形和不均勻的壁厚，導致縮孔和氣孔等缺陷很容易出現(xiàn)。而且油泵壓鑄件的密封要求非常高，所以鑄件需要通過高水壓測試，且要求無任何泄漏。借助于CAE軟件的模擬和分析來優(yōu)化壓鑄件的設計，可以使壓鑄產(chǎn)品的合格率在較短時間內得到大大提高。</p>

51、<p>　　3.3、CAM的應用</p><p>　　首先運用Pro/ENGINEER的CAD/CAM軟件的Pro/MANUFACTURING模塊，在壓鑄模具型腔三維實體造型的數(shù)據(jù)基礎上，新建一個三維實體造型鑲嵌加工空白頁。然后，制作一個加工工藝表，包括加工余量，刀具，刀具路徑等，同時還要創(chuàng)建一個NC（數(shù)控）切割程序和CL（銑刀）數(shù)據(jù)文件。此外由于NC 檢查模塊的使用，可以對加工刀具路徑進行檢查和觀察

52、瞬時加工工藝過程。數(shù)控切割過程中的各CL數(shù)據(jù)文件可以進行修改，直到達到一個滿意的結果。這時CAM軟件將及時對這些數(shù)據(jù)進行處理并傳送到數(shù)控機床代碼庫。壓鑄模具外殼蓋的鑲嵌加工刀具路徑如圖7所示。</p><p>　　4、集成系統(tǒng)的應用總結</p><p>　　綜上所述，借助于Pro/ENGINEER的CAD/CAM軟件和主要專業(yè)軟件系統(tǒng)包的幫助，建立壓鑄模的三維實體造型和設計壓鑄工藝的技術方

53、案。然后使用MAGMASOFT軟件對模具中金屬液的流動和凝固進行模擬和分析，對壓鑄的技術方案和工藝參數(shù)進行修改和優(yōu)化。這樣就完成了模具完整的三維實體造型。最后創(chuàng)建模具和型芯復雜表面的CAM加工數(shù)據(jù)，所有CAM加工數(shù)據(jù)都在數(shù)控機床上完成。由于在整個過程中使用的是同一三維模型的數(shù)據(jù)庫，一些步驟可以同時進行，可以明顯縮短模具的設計和制造周期。</p><p>　　通過CAE模擬軟件對壓鑄工藝的技術方案和工藝參數(shù)進行修改

54、和進一步的優(yōu)化，壓鑄件的質量在較短的時間里得到很大提高。例如，由于使用CAE進行模擬，上面提到的壓鑄件油泵的產(chǎn)品合格率在較短的時間里從60%提高到90%。</p><p>　　另一個例子是汽車變速箱殼體的鎂合金壓鑄件。CAE模擬結果表明，模具型腔內的溫度分布不均勻。通過調節(jié)工藝參數(shù)，如注射速度，冷卻介質的流速，可以改善熱平衡和溫度分布，也減小裂縫出現(xiàn)的可能性。由于壓鑄件的產(chǎn)品合格率在較短的時間里得到很大提高，整個

55、壓鑄件的交貨時間也就大大縮短。</p><p><b>　　5、結論</b></p><p>　　壓鑄模的CAD/CAE/CAM集成系統(tǒng)目前已成功地應用在汽車壓鑄件的設計和制造中，如油泵，變速箱殼體等壓鑄零件。壓鑄件的壓鑄模具的設計和制造周期明顯縮短。借助CAE模擬技術可以優(yōu)化壓鑄件的工藝參數(shù)和技術方案。它的作用是可以在較短的時間里是生產(chǎn)出高質量的壓鑄件，交貨時間也大

56、大縮短。然而，該集成系統(tǒng)還需要進一步研究和開發(fā)，特別是專業(yè)軟件系統(tǒng)部分。同時需要對更多成功地應用在實際生產(chǎn)中的壓鑄件資料，包括專業(yè)軟件系統(tǒng)中壓鑄件的資料進行分析。這些將有助于完善該專業(yè)軟件系統(tǒng)包。</p><p><b>　　參考文獻</b></p><p>　　[1] K. Chipley, S. Viswanathan, R.H. Cooper, Die Cas

57、t. Eng. 40 (2)</p><p>　　(1996) 18–26.</p><p>　　[2] P.M. Bralower, Die Cast. Eng. 42 (5) (1998) 16–20.</p><p>　　[3] S.P. Midson, Die Cast. Eng. 38 (5) (1994) 42–46.</p><