Research On Numerical Simulation Of Steel Casting Of Lost Foam Casting

The mold filling course is closely related to quality of the casting, it is an important condition of obtaining the high-quality casting to understand and control the mold filling course. Through the simulation of the mold filling course, the formative mechanism of the main casting defects were grasped, the casting technology parameter can be optimized, the quality of castings will be guaranteed,the trial-produce cycle can be shorten,and the productive cost would be reduced.In this paper,adopting Pro/E 3D software and using the famous ProCAST software of French ESI company as simulation tool in the casting process , the lost foam casting(LFC) of Steel casting has been carried on the simulation analysis.First of all, the two softwares were introduced briefly, and the interfaces has been deeply researched between the two software. The massive practices indicate that the best connection way to use the Shell form to output the PATRAN form surface grid, cuts in half the body grid by MeshCAST.Secondly, using the ProCAST simulation software, through the simulation on the filling process of thin plate steel casting LFC, has analyzed flow pattern during the filling process, filling velocity (through filling time reflection), as well as gap thickness between liquid metal and foam pattern.The conclusions are as follows:1. Back pressure resistance on molten metal of the pyrolysis gas is internal factor ,which makes LFC different to the ordinary sand casting. During the LFC filling process, the molten metal assumes radiated from the ingate fills forward, the filling is steady, which has avoided the liquid flow inertia and the action of gravity creates to the cast the impact.2. Reasonable choice technological factors, such as foam density, pouring temperature, vacuum degree and so on are profound to the steel casting filling influence significance. Speaking of the steel casting, along with foam density's enlargement, its filling velocity reduces; Along with pouring temperature's elevation, its filling velocity is increases at first, the pouring temperature elevates after certain value, its filling velocity instead reduces;Along with vacuum degree's elevation, its sufficient speed is increases at first, after vacuum degree up to certain value, the filling velocity instead reduces.3. In the LFC between the molten metal and froth appearance's gap thickness is important, oversized, too small does not favor the production; Gap thickness and foam density are in reverse proportion; Must choose the foam reasonably.Lastly, take some aluminum manufacturer electrolytic aluminium with the anode steel fingernail as the example,and set a CAD model.By measuring actual working condition,we set up a material database for casting and sand mold. Through choose reasonable model and parameters, we have simulated the casting process successful.