The Mold Design And Casting Process Simulation Of Complex Cylinder Block In Lost Foam Process

Compared with the traditional sand casting, the lost foam casting (LFC) has lots ofadvantages, such as no parting or cores, high dimensional accuracy, good surface quality,low cost and so on. It is suitable for the production of complex cylinder block castings.But for a complex cylinder block, the LFC also has some problems, such as a long periodof lost foam mold design, mold change inconvenient, existing gas hole and sticky sand inthe casting products and so on, which restricts the development of LFC technology andapplications.For a typical diesel cylinder block, the lost foam mold design, development of themold design and lost foam casting process simulation, etc. were studied in this thesis.Firstly, based on UG modeling module, according to the characteristics of thecomplex cylinder block and lost foam mold, a typical cylinder block and its lost foammold was designed by the parametric design method combined with the assembly andwave technology, which shortened the design cycle of lost foam mold and facilitated themodify of the product and mold.Secondly, based on UG software platform, lost foam mold design was explored bythe use of UG OPEN tool. The design of initial lost foam mold-aided design systems wascompleted in order to reduce repetitive and mechanical work in the lost foam mold designand improve the efficiency of the mold design. And a steam room template was designedusing parametric design method which made modification easy and quickly.Finally, based on general simulation software, comparison experiments of lost foamcasting process simulation of the cylinder block were carried out in different castingconditions, in order to optimize the casting temperature and vacuum degree, etc. for thecylinder block and guide the actual production.