Numerical Simulation and Process Optimization of Magnesium Alloy Vehicle Dashboard Cross Car Beam (CCB) Based on MAGMA
Abstract
:1. Introduction
2. Materials and Methods
2.1. Materials and Modeling
2.2. Response Surface Test Design
2.3. Die Casting Experiment
3. Results and Discussion
3.1. Simulation Analysis of Die Casting Filling
3.1.1. Filling Temperature Simulation
3.1.2. Filling Speed Simulation
3.2. Response Surface Test Results and Analysis
3.2.1. Response Surface Model for Air Entrapment Rate
3.2.2. Response Surface Model for Shrinkage Cavity Rate
3.3. Simulation Analysis
3.4. Die Casting Experiment
4. Conclusions
- (1)
- Under the same process parameters, MAGMA software was used to simulate the filling of two pouring system schemes for CCB of magnesium alloy automobiles, and the results showed that the design of the pouring system of scheme 2 was better than that of scheme 1, and the design of scheme 2 could effectively reduce casting defects.
- (2)
- In the die-casting process of the AM60B magnesium alloy automotive CCB bracket, when only the air entrapment rate is considered, the press injection speed has the greatest influence, the mold preheating temperature is second, and the pouring temperature has the least influence. When considering only the shrinkage cavity rate, the pouring temperature has the greatest influence, the mold preheating temperature is second, and the press injection speed has the least influence.
- (3)
- In the actual production process, the air entrainment rate and shrinkage cavity rate should be considered comprehensively. The optimal combination of process parameters is as follows: pouring temperature 660 °C, mold preheating temperature 200 °C, and press injection speed 6.5 m/s. Under these process parameters, the qualified rate of magnesium alloy CCB castings can be improved effectively.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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Element | Al | Zn | Mn | Si | Fe | Cu | Ni | Be | Mg |
---|---|---|---|---|---|---|---|---|---|
Proportion (%) | 5.8 | 0.18 | 0.56 | 0.08 | 0.0003 | 0.006 | 0.00086 | 0.0012 | Bal. |
A | B | C | |
---|---|---|---|
Pouring Temperature (°C) | Mold preheating Temperature (°C) | Injection Speed (m/s) | |
Level 1 | 660 | 160 | 4.5 |
Level 2 | 680 | 180 | 5.5 |
Level 3 | 700 | 200 | 6.5 |
Serial Number | Pouring Temperature (°C) | Mold Preheating Temperature (°C) | Injection Speed (m/s) | Air Entrapment (%) | Shrinkage Cavity (%) |
---|---|---|---|---|---|
A | B | C | Y1 | Y2 | |
1 | 660 | 160 | 5.5 | 1.47 | 0.401 |
2 | 700 | 160 | 5.5 | 1.46 | 0.537 |
3 | 660 | 200 | 5.5 | 1.44 | 0.334 |
4 | 700 | 200 | 5.5 | 1.44 | 0.457 |
5 | 660 | 180 | 4.5 | 1.58 | 0.365 |
6 | 700 | 180 | 4.5 | 1.55 | 0.479 |
7 | 660 | 180 | 6.5 | 1.38 | 0.368 |
8 | 700 | 180 | 6.5 | 1.37 | 0.48 |
9 | 680 | 160 | 4.5 | 1.59 | 0.463 |
10 | 680 | 200 | 4.5 | 1.54 | 0.393 |
11 | 680 | 160 | 6.5 | 1.39 | 0.465 |
12 | 680 | 200 | 6.5 | 1.36 | 0.395 |
13 | 680 | 180 | 5.5 | 1.45 | 0.423 |
14 | 680 | 180 | 5.5 | 1.46 | 0.419 |
15 | 680 | 180 | 5.5 | 1.45 | 0.418 |
16 | 680 | 180 | 5.5 | 1.45 | 0.413 |
17 | 680 | 180 | 5.5 | 1.45 | 0.423 |
Source | Sum of Squares | df | Mean Square | F-Value | p-Value | Statistical Significance |
---|---|---|---|---|---|---|
Model | 0.0762 | 9 | 0.0085 | 194.29 | <0.0001 | Significant |
A | 0.0003 | 1 | 0.0003 | 7.17 | 0.0316 | |
B | 0.0021 | 1 | 0.0021 | 48.48 | 0.0002 | |
C | 0.0722 | 1 | 0.0722 | 1657.05 | <0.0001 | Significant |
AB | 0 | 1 | 0 | 0.5738 | 0.4735 | |
AC | 0.0001 | 1 | 0.0001 | 2.3 | 0.1736 | |
BC | 0.0001 | 1 | 0.0001 | 2.3 | 0.1736 | |
A2 | 2.632 × 10−7 | 1 | 2.632 × 10−7 | 0.006 | 0.9402 | |
B2 | 2.632 × 10−7 | 1 | 2.632 × 10−7 | 0.006 | 0.9402 | |
C2 | 0.0013 | 1 | 0.0013 | 30.45 | 0.0009 | Significant |
Residual | 0.0003 | 7 | 0 | |||
Lack of fit | 0.0002 | 3 | 0.0001 | 3.75 | 0.1171 | |
Pure error | 0.0001 | 41 | 0 | |||
Cor total | 0.0765 | 6 |
Source | Sum of Squares | df | Mean Square | F-Value | p-Value | Statistical Significance |
---|---|---|---|---|---|---|
Model | 0.0402 | 9 | 0.0045 | 148.17 | <0.0001 | Significant |
A | 0.0294 | 1 | 0.0294 | 975.23 | <0.0001 | Significant |
B | 0.0103 | 1 | 0.0103 | 341.5 | <0.0001 | Significant |
C | 0.000008 | 1 | 0.000008 | 0.2653 | 0.6223 | |
AB | 0 | 1 | 0 | 1.4 | 0.2751 | |
AC | 0.000001 | 1 | 0.000001 | 0.0332 | 0.8607 | |
BC | 0 | 1 | 0 | 0 | 1 | |
A2 | 0.0001 | 1 | 0.0001 | 1.74 | 0.2292 | |
B2 | 0.0004 | 1 | 0.0004 | 12.67 | 0.0092 | Significant |
C2 | 3.184 × 10−7 | 1 | 3.184 × 10−7 | 0.0106 | 0.921 | |
Residual | 0.0002 | 7 | 0 | |||
Lack of fit | 0.0001 | 3 | 0 | 2.76 | 0.1761 | |
Pure error | 0.0001 | 4 | 0 | |||
Cor total | 0.0404 | 16 |
Air Entrainment or Shrinkage | Qualified Product | |
---|---|---|
Before optimization | 85 | 15 |
After optimization | 6 | 94 |
Tensile Strength (MPa) | Yield Strength (MPa) | Elongation (%) | |
---|---|---|---|
After optimization | 190.24 | 79.76 | 3.2 |
191.52 | 81.35 | 4.2 | |
184.58 | 78.94 | 5.8 | |
Before optimization | 221.19 | 103.64 | 9.4 |
215.34 | 106.74 | 10.6 | |
218.96 | 98.74 | 9.8 |
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Li, J.; Chen, L.; Jiang, S.; Gan, H.; Hao, W. Numerical Simulation and Process Optimization of Magnesium Alloy Vehicle Dashboard Cross Car Beam (CCB) Based on MAGMA. Processes 2023, 11, 16. https://doi.org/10.3390/pr11010016
Li J, Chen L, Jiang S, Gan H, Hao W. Numerical Simulation and Process Optimization of Magnesium Alloy Vehicle Dashboard Cross Car Beam (CCB) Based on MAGMA. Processes. 2023; 11(1):16. https://doi.org/10.3390/pr11010016
Chicago/Turabian StyleLi, Jiquan, Long Chen, Shaofei Jiang, Huiqi Gan, and Weina Hao. 2023. "Numerical Simulation and Process Optimization of Magnesium Alloy Vehicle Dashboard Cross Car Beam (CCB) Based on MAGMA" Processes 11, no. 1: 16. https://doi.org/10.3390/pr11010016
APA StyleLi, J., Chen, L., Jiang, S., Gan, H., & Hao, W. (2023). Numerical Simulation and Process Optimization of Magnesium Alloy Vehicle Dashboard Cross Car Beam (CCB) Based on MAGMA. Processes, 11(1), 16. https://doi.org/10.3390/pr11010016