Research On Digital Casting System For Sprue Gate And Riser Process Of Cylinder Block Iron Castings

The medium and large engines,the important sources of power for mechanical equipment and an indispensable part of human-beings activities in industrial and agricultural production,have had extensive industrial applications in lots of fields such as automobiles,ships,engineering and agricultural machinery,which are of great strategic significance in national economy and defense industry.The cylinder block iron casting,as one of core components of engine,which have high internal quality requirements,complicated and difficult production process,and a large number of core manufacturing technologies,is typical representative of complex structural parts in foundry industry.At present,the determination,selection,design and implementation of cylinder block iron casting are generally dependent on the experience of workers.The process varies greatly,the digitization is low,and the repeatability is poor.The repeated debugging process will also change due to casting structure adjustment or production conditions change instable,resulting in the difficulty of new production development,precise design of sprue gate and riser process,poor casting quality stability,and high reject rate.Therefore,it is very important to sum up and analyze the casting process of engine cylinder block and summarize the design principles of typical casting process.Besides,it is possible to establish a digital casting system and improve the digitization and information of cylinder block casting process based on computer technology.The article utilizes method based on mathematical statistics to research casting process.Its basic idea is based on production practice of cylinder block iron casting of foundry enterprises,making full use of large amount of data information and successful experience of manufacturer,combining achievements of academic community,adopting methods of statistical research and data analysis to analyze the cases,to summarize the typical sprue gate and riser process of cylinder block iron casting,and to revise process design method of cylinder block iron casting.There are 50 typical cases of collection in cylinder block iron casting.On the basis of typical cases of collected cylinder block iron casting,the methods of sorting the materials and ranking the quality of the castings are used to arrange the similar technologies.The in-depth mathematical statistical analysis has been carried out for casting process of cylinder block iron casting based on the small sample theory.Taking the shrinking module coefficient as a reference,the status of design of the riser feeding process for cylinder block iron castings are analyzed to determine the rationality of design of the feeding riser.And the production application of feeding riser process for cylinder block iron castings are added up,and the in-depth analysis of riser process design has been carried out for cylinder block iron castings.Based on the theory of large-hole outflow,the application and effect of gating process of cylinder block iron castings are analyzed to statistics the intrinsic statistical laws and design principles of gating process parameters of cylinder block iron castings in-depth.The casting process model of sprue gate and riser of cylinder block iron casting was established,and the typical process and application range of sprue gate and riser of cylinder block iron casting were summarized.Based on the typical process of cylinder block iron castings,the database of casting process is designed and developed,and the digital sprue gate and riser system of cylinder block iron casting is built to realize digital design of sprue gate and riser system of cylinder block iron casting in order to guide the accurate forming and quality control;The digital sprue gate and riser system of cylinder block iron casting is used as a tool to realize the digital design and precise control of the shape for sprue gate and riser system of typical engine cylinder block iron casting(HT200),and complete gating test of typical engine cylinder block iron casting.Sampling is performed on the important areas of the engine block cast iron parts(crankshaft connection points).In summary,this article has conducted in-depth research on the digital sprue gate and riser system of engine cylinder block iron casting,which can provide theoretical guidance and solutions for realizing the digital design and precise control of the shape for sprue gate and riser system of engine cylinder block iron casting.It is of great significance to overcome the limitations of relying solely on limited experiments and effectively shorten the gap between research results and production applications,and to improve the quality of cylinder block iron casting and promote the digitization and green development of the casting process.