Typical Steel Casting Technologyanalysis And Improvement Based On Numerical Simulation

Solidification is the key process to steel castings'quality, many casting defects such as shrinkage, porosity, transfiguration and so on are brought in this process or have close relation with it. After the liquids flow into the mold cavity, how does the temperature change, how does the solidification process and how do the defects form, etc all are invisible processes to the casting workers. By scientific calculation and vivid description to optimize the best plan and form the technical documents in order to produce excellent casting with less materials and manpower is the main task of the casting solidification's numerical simulation.My paper is to forecast the typical steel castings'quality based on numerical simulation. Utilizing the numerical simulation technology of computer to forecast the casting defects, such as shrinkage, porosity, ect of the typical steel castings in the production in order to optimize the technics and reduce the casting cost. By simulation analyses and experimental inspection of the two chosen steel casings to make the numerical simulation applies to the practical production better.Twist drill castings are a critical component in the coal mining machine. The operate environment of twist drill mining machine are very bad. The twist drill castings are touched with stones and others mediums. The castings inside quality are important in order to avoid twist drill castings broken. Thus, improve the castings inside quality means improve the mining efficiency.The engineer of this foundry made pouring system to twist drill castings. We simulated the original pouring system use the Procast software. It forecast the possible location of the shrinkage defects. Based on the simulation results, we improved the pouring system. At the same time, we also run a simulation to the updated pouring system, until we not found any defects. We poured casting samples according to the new pouring system. We did the X-ray test, UT test and section test to this castings. The inspection results are good!The cone crusher are widely using in the field of metallurgy industry, architecture industry, chemical industry. The cone crushers are suitable to break the ore and stone with high hardness. The most important equipment is mortar rolled castings. As the mortar rolled castings are direct touched with ore and stones, and it bears the press and others strengths. The mortar rolled castings not only need high hardness and Charpy properties, but also need good casting inside quality. We once found some factory replace the mortar rolled castings advanced due to the castings inside quality are not good. The bad inside quality castings not only bring lots of waste, but also reduce the cone crusher work efficiency.We simulated the original pouring system to the castings of mortar rolled use the Procast software. It forecast some locations will have shrinkage defects. Based on the simulation results, we improved the pouring system. At the same time, we also run a simulation to updated pouring system. We not found any defects. We poured casting samples according to the new pouring system. We did section test to this castings. The inspection results are good! The methods are not only improving the accuracy of pouring system design, but also save lots of cost of actual pouring.Through the numerical simulation to above typical steel castings'solidification process, it has put the numerical simulation into practical application in the production and has avoided the blindness of technical designs, also shortened the design period of new technical and the design cost. Utilizing the pre-producing of computers can advance the precision of technical, which has an important meaning to improve the economical benefits and enhance the competition of the enterprise.