铝车轮低压铸造质量调控的机器学习模型研究

Research on Machine Learning Model for Quality Control in Low-Pressure Die Casting of Aluminum Wheels

  • 摘要: 铝车轮轻量化要求严苛,且造型复杂,极大地增加了制造难度。低压铸造(low pressure die casting, LPDC)作为最广泛的铝车轮制造技术,模温精准预测和铸件质量控制一直是行业难题。本文基于铝车轮低压铸造生产大数据,搭建了卷积神经网络联合长短期记忆网络(convolutional neural network-long short-term memory network, CNN-LSTM)的机器学习模型,建立了铸造工艺-模具温度-铸件质量的内在联系。结果表明:通过CNN-LSTM模型可以实现对不同压铸工艺下模具轮辐位置温度进行预测,模温实测值与预测值的均方根误差为2.82 ℃。以合格铝合金车轮的模具温度曲线为控制目标,在铸造过程中进行适时工艺参数调整可有效避免铸造缺陷产生。通过对比传统铸造工艺与机器学习模型驱动的新型铸造工艺下的铝车轮铸造质量,发现新型铸造工艺铝车轮轮辐力学性能获得明显提升,抗拉强度和延伸率较传统工艺分别提高了19.5 MPa和3.8个百分点。

     

    Abstract: Aluminum wheels are subject to stringent lightweight requirements and feature complex geometries, which significantly increases manufacturing difficulty. Low pressure die casting (LPDC), as the most widely used manufacturing technology for aluminum wheels, has long faced industry challenges in accurate mold temperature prediction and casting quality control. Based on big data from aluminum wheel low-pressure die casting production, this study establishes a machine learning model combining convolutional neural network and long short-term memory network (CNN-LSTM), revealing the intrinsic relationship among casting process, mold temperature and casting quality.The results show that the CNN-LSTM model can accurately predict the temperature at the wheel spoke position of the mold under different die casting processes, with a root mean square error of 2.82 ℃ between measured and predicted mold temperatures. Taking the mold temperature curve of qualified aluminum alloy wheels as the control target, timely adjustment of process parameters during casting can effectively avoid the formation of casting defects. By comparing the casting quality of aluminum wheels produced under the traditional casting process and the novel machine learning model-driven casting process, the mechanical properties of wheel spokes are significantly improved by the novel process. The tensile strength and elongation at fracture are increased by 19.5 MPa and 3.8 percentage points compared with the traditional process.

     

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