Application Of PROCAST On The Bogies Manufacturing Process

Key parts of bogie are manufactured through flask mold process of furan resin and self hardened sand. According to the info of wagon operation and delivery inspection, the key issues of bogie production properly are the casting defects, such as shrinkages and cracks. Concerning the issues, it is decided that numerical simulation should be applied during the process design of bogie castings. This article is to analyze and simulate the manufacturing process of sideframe, which is the key parts of bogie, through secondly developed ProCAST software. On the basis of the theory –Numerical Simulation Technology for casting process, this article expounds how the ProCAST to detect temperature, fluid and stress field by mathematics and physics model through finite element method (FEM)so as to figure out casting defects. It is for further grasp the software of ProCAST to set up the foundation for second development and further application. In order to solve the interface problem between ProCAST and Pro/E of a 3D designing software, the Shell Model is invented creatively during the researching. Not only it is the simple mould designing and no parting surface concerned between casting and mould while FEM model is establishing, but also variable materials for castings can be confirmed automatically. Therefore the problem involved in professions for many years that data transfer from geometrical model of complex castings to finite element analytic model is resolved sufficiently. Thermal parameters are so important in numerical simulation. An applicable database of thermal parameters and that of casting-mould thermal exchange coefficients are obtained during the practice and entrusted tests especially for the production of QRRS bogies castings. The parting face between casting and mould is divided as contact region and air gap region. In order to apply the simulation system into QRRS Current Engineering Project and to solve the problem of integration of CAD/CAE system, the function model is re-designed for the project so as to legalize the process on product developing. Meanwhile various concerned factors all the time in life cycle of castings have been fully considered during production process. On the basis of Second Developing and according to the process requirement of ProCAST for castings (side frame)to be supplied to Australia, The basic model block, fluid analysis, model block and stress analysis model block are applied to analyze fluid, temperature and stress when the casting is solidifying so as to predict shrinkage, dispersed shrinkage, hot tears and other defects of these castings, being a scientific base for bogie castings manufacturing. Through Numerical Simulation, which provides the improving solution, the casting process is optimized making complicated key parts of the bogies passed inspection and accepted at one time. The preparation time for process is dramatically shortened and the cost of trial-production is reduced, saving valuable time for the export of rolling stock to Australia.