Optimization of squeeze casting process of gearbox cover based on FEM and Box-Behnken design

• Published in: International journal of advanced manufacturing technology Vol. 118; no. 9-10; pp. 3421 - 3430
• Main Authors: Li, Junhong, Sun, Yu, Wang, Yu, Sun, Jue
• Format: Journal Article
• Language: English
• Published: London Springer London 01.02.2022; Springer Nature B.V
• Subjects: Airtightness; CAE) and Design; Casting; Casting defects; Casting machines; Computer-Aided Engineering (CAD; Design defects; Design of experiments; Engineering; Finite element method; Gearboxes; Industrial and Production Engineering; Mathematical models; Mechanical Engineering; Media Management; Melt temperature; Molds; Optimization; Original Article; Porosity; Process parameters; Regression analysis; Response surface methodology; Shrinkage; Simulation; Squeeze casting; Variance analysis; X ray inspection; Numerical simulation; Process optimization; BBD; ANOVA; Squeeze casting
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-021-08099-8

In order to solve the casting defects of the gearbox cover to meet the requirements of high performance and high air-tightness, the ProCAST was taken to simulate the squeeze casting process and predict the position of shrinkage defects accurately. For the purpose of efficiently exploring the optimal process parameters to eliminate defects, response surface methodology (RSM) was used to design the numerical simulation scheme. Seventeen simulation trials in total had been conducted according to Box-Behnken experimental design (BBD) which contained three process parameters (mold temperature, alloy temperature, and squeeze pressure) while recording the response of the gearbox cover shrinkage porosity. Analysis of variance (ANOVA) was employed to evaluate the significance and prediction capability of mathematical models developed through regression analysis. The results indicate that the three process parameters are significant and the shrinkage porosity reaches the minimum when the mold temperature is 341.74℃, the melt temperature is 697.33℃, and the squeeze pressure is 107.03 MPa. Aiming at verifying the optimal parameters, the trial production test was carried out on the squeeze casting machine SCH-1000. And X-ray inspection shows that the cover has no casting defects.