CAD/CAE Of Permanent Molds Casting Process For Rail Drill House & Cover Of Aluminum Alloy And Optimization

House and cover are the main parts of rail drill and have high quality requirements, so they need cast by precision casting process. In order to improve product quality and shorten development cycle, CAD and CAE have been applied to the permanent mold design and manufacture for aluminum alloy.Based on the three-dimensional CAD software Unigraphics NX2.0 platform, the three-dimensional models of house and lid have been built, the two-dimensional drawings of cast house and cover have been supplied, two sets of permanent molds and two sets of core boxes of sand have been designed. The whole design becomes fast and vivid. And it will also bring the sufficient data for the solidification simulation and mold manufacture.The application of HuaZhu CAE/ InteCast has been systematically studied. The castings of house and cover have been simulated and permanent molds of house and cover have been verified. The HuaZhu CAE/ InteCast software is used to make the casting process and tool design of house and lid optimized constantly.Many casting experiments of house and cover have been conducted. In view of all kinds of defects of the casts of house and cover, the structures and gating system of permanent molds have been changed multiple times. The suitable casting process has been proposed that the mold temperature is 250℃and the melt temperature is 720℃. The suitable way of mold coating spray has been mastered. The supporting bosses of resin bonded sand have been adopted to solve the eccentricity of resin bonded sand core. The product quality of aluminum alloy casting has been improved and stabilized.The results of cast experiment and CAE simulation have been compared. The insulating sleeve has been adopted to replace the insulating coatings for better simulation result. The suitable original simulation data has been found and it will be better to instruct cast experiment.