Optimization Design of Casting Process for Large Long Lead Cylinder of Aluminum Alloy

As the core component of chain-less ammunition transmission system, the large long lead cylinder adopts ZL205A alloy, which has the advantages of high strength and wear resistance. However, in its main casting production process, the forming quality is mainly determined by the casting process parameters under the premise of determining a reasonable casting system. Considering that the casting process parameters are the process feedback expression of the macroscopic forming quality and comprehensive mechanical properties by controlling the coupling effect of the metal liquid flow in the microscopic flow field, the directional solidification crystallization of the alloy and the solid-liquid heat transfer and heat transfer during the filling and solidification process, the accurate and reasonable selection of casting process parameters is conducive to the stable guarantee of pouring quality. On the basis of the optimized column gap casting system, this study combined numerical simulation and data statistics. Within the rationality of each casting process parameter constructed by single-factor analysis, the response surface method was used to construct a quantitative guidance relationship of each process parameter coupling mapping casting defect, and based on this model, the optimal process parameter combination was realized as follows: compared with traditional metal mold casting and unoptimized low pressure casting, the tensile strength of non-porous casting with holding pressure 14.68 kPa, casting temperature 717.152 °C and mold preheating temperature 256.12 °C increased by 6.6% and 4.1%, respectively, hardness increased by 14.3% and 8.4% respectively, and the elongation is increased by 16.9% and 10.6%, respectively, thus efficiently and accurately improving the process quality.