采用Flow-3D软件建立了ADC12铝合金车门内板挤压铸造过程的有限元模型, 探讨了模具温度、浇注温度和压机下压速度对熔体充型状态的影响, 对挤压铸造工艺进行了优化, 并进行了试验验证。结果表明: 浇注温度高于953 K, 充型结束时低于固相线温度的区域逐渐减小; 模具温度会影响铸件充型边缘区域的温度; 高速下压会产生过多的气孔、氧化渣夹杂, 不利于铸件顺序凝固; 当浇注温度不低于953 K, 模具温度不低于583 K, 压机下压速度为24 mm·s-1时, 可以成功制备结构完整的铝合金车门内板铸件; 试验结果证明了模拟结果的正确性。

A simulation model of squeeze casting for aluminum alloy inner door panel was established based on Flow-3D software. The effects of die temperature, pouring temperature and punch speed on filling process were investigated, the squeeze casting process was optimized and experiment verification was carried out. The research results show that when pouring temperature was higher than 953 K, the region below solidus temperature decreased gradually at the end of filling. The temperature of casting edge was affected by die temperature. High pressing speed led to many holes and slag inclusions, and those were bad to the filling sequence. With the combination of pouring temperature (no less than 953 K), die temperature (no less than 583 K), punch speed (24 mm·s-1), the aluminum alloy inner door panel could be manufactured with a integrate shape. The correctness of simulated results was proved by the experimental ones.