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Research on the squeeze casting process of large wheel hub based on FEM and RSM

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Abstract

To obtain a high-performance 18-inch wheel hub to meet the automobile lightweight requirements, it is necessary to develop and optimize the squeeze casting process. Firstly, heat exchange channels were added to make the casting meet the principle of sequential solidification according to the thermal–fluid coupling simulation results based on FEM. And the positions of shrinkage defects were predicted accurately. To efficiently explore the optimal process parameters to eliminate defects, response surface methodology (RSM) was used to design the numerical simulation scheme. Thirty simulation trials had been conducted which contained four process parameters (mold temperature X1, alloy temperature X2, squeeze speed X3, and squeeze pressure X4) while recording the response of total shrinkage porosity. Analysis of variance (ANOVA) was employed to evaluate the significance and prediction capability of mathematical models developed through regression analysis. The response reaches the minimum when the four significant parameters X1 is 297.58℃, X2 is 691.59℃, X3 is 0.085 m/s, and X4 is 131.97 MPa. Aiming at verifying the optimal parameters, the trial production test was carried out on machine SCH-3500. The X-ray inspection shows the wheel hub has no casting defects. Additionally, the weight is reduced by 11.2% while the mechanical properties are higher.

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Funding

This work is supported by the National Major Science and Technology Projects of China (CN) (award number 2019ZX04029-001).

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Authors and Affiliations

  1. School of Mechanical Engineering, Nanjing University of Science and Technology, Nanjing, China

    Junhong Li, Yu Sun & Yu Wang

  2. Ningbo Jianxin Chassis System Co., Ltd., Ningbo, China

    Lei Zhang

  3. Sanji Foundry Equipment Co., Ltd., Suzhou, China

    Jue Sun

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  1. Junhong Li
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  2. Yu Sun
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  3. Yu Wang
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  4. Lei Zhang
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  5. Jue Sun
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All authors contributed significantly to the work with the order provided.

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Correspondence to Yu Sun.

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Li, J., Sun, Y., Wang, Y. et al. Research on the squeeze casting process of large wheel hub based on FEM and RSM. Int J Adv Manuf Technol 128, 197–208 (2023). https://doi.org/10.1007/s00170-023-11740-3

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  • DOI: https://doi.org/10.1007/s00170-023-11740-3

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