Application Of Numerical Simulation In Casting Process Optimization Of Cast Steel Axle Housing And Predicting Method For Shrinkage Cavity And Porosity

It is well known that the axle housing is a very important part in the vehicle, especially for the cast steel axle housing used in the mining engineering car. The cast steel bridge shell has the characteristics of large size complicated structure,difficult to control in the casting process,It will produce various casting defect. With the rapid development of computer simulation technology, casting process simulation technology has become an important tool to guide the actual production of foundry enterprises. In order to shorten the development cycle and reduce the development cost of casting steel bridge shell, the filling and solidification process of cast steel bridge shell is analyzed by numerical simulation software in the process of casting process design, which has important guiding effect on actual production.Based on CATIA and ProCAST, the solid model was established, and the process of filling and solidification was simulated. The process of casting defects was reproduced. By analyzing the typical defects such as shrinkage, shrinkage and thermal cracking in cast steel bridge shell casting process The main reason, improve the gating system design, optimization of the casting process, thereby reducing the rejection rate.According to the structure of cast steel axle housing, the design of casting system, the layout of the gate, runner, to determine the initial casting process. The casting process was simulated by CATIA software. The simulation results show that shrinkage porosity and shrinkage defects mainly appear in the two ends and the middle part of castings.In this paper, by adding ordinary riser and insulation riser at both ends of the casting to solve the shrinkage and shrinkage defects at both ends of the casting, the simulation results and the initial plan are contrasted. It is found that the riser effectively leads the shrinkage to the outside of the casting, The possibility of defects inside the casting is reduced, which indicates the purpose of optimizing the design of the riser.In this paper, by changing the core sand material, the middle part of the casting shrinkage porosity was significantly reduced. The results show that the high temperature mechanical properties and the thermo-physical properties of the sand samples have a great impact on the accuracy of the numerical simulation results.Finally, the final program is put into actual production, and the experimental results are compared with the simulated results. The results are in agreement with each other, and the correctness of the final scheme is verified. It is proved that the numerical simulation technology can save the cost and shorten the trial-manufacture period, and bring huge profit for the company.