상용 모델링 소프트웨어를 사용하여 기공 수준을 예측하는 고압 다이캐스트 알루미늄 스윙 암의 응고 거동에 대한 연구

Nitin Choudhari & Dinesh Y. Dhande

Abstract

자동차 산업에서 알루미늄 주조는 구조적 구성 요소에 일반적으로 사용되는 생산 공정입니다. 그러나 알루미늄 주조의 결함은 피로 파괴로 이어질 수 있습니다. 이 연구 조사는 알루미늄 다이캐스트(HPDC)로 만든 스윙 암의 설계, 개발, 구성 및 테스트에 대한 철저한 분석을 제공합니다. 이 조사는 주로 기공 길이, 응고 시간, 핫스팟 분포 및 수축 기공 강도와 같은 요인을 철저히 조사하여 스윙 암의 응고 거동을 분석하는 데 중점을 둡니다. 상용 시뮬레이션 소프트웨어인 Magma 5를 사용하여 관찰된 오류를 해결하기 위해 설계 수정을 용이하게 했습니다. 설계 수정을 통해 응고 시간이 상당히 단축되어 이전에 식별된 균열 영역에서 핫스팟이 이동했습니다. 또한 기공 비율과 강도가 모두 상당히 감소했으며 이는 X선 및 CT 스캔 분석을 통해 확인되었습니다. 동력계로 내구성 테스트를 수행한 후 원래 설계와 비교했을 때 피로 수명이 50%나 크게 증가한 것을 발견했습니다.

이 연구는 HPDC 알루미늄 구조물의 피로 파괴를 해결하는 데 있어 초기 단계 시뮬레이션 기반 설계 조정의 중요성을 강조합니다. 8%를 초과하는 과도한 다공성 수준이 이 문제에 기여하는 주요 요인이라는 점이 확인되었습니다. 제안에는 다공성을 줄이기 위해 더 두꺼운 구조와 부품 설계의 복잡성을 피하는 것이 포함됩니다. 표면 근접성 및 구조적 응력 구역과 관련하여 결함의 위치를 ​​고려하는 것도 중요합니다.

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