Design For Pouring And Feeding Systems Of The Ductile Iron Hub In 1.5MW Wind Power Generation Unit

Nowadays, as the oil and gas energy are exhausted, it is an important practical significance to research wind power problem. Wind turbine's hub ductile iron casts is the most important part in wind power generation unit. It is one of the key factors to determine the quality of the wheel hub. The diameter of fan wheel castings is about 3 meters, about 8 tons weight, the important wall thickness is more than 160 millimeter,it is extremely hard to cast in a whole. Compared with traditional methods, it has many davantages such as low cost, short developed cycle, scientific and reliable research results by using computer simulation of methods study casting process optimization problem.In this paper, research of casting filling process and solidification process are carried out with the computer simulation method to achieve the purpose of optimized casting process. The foundry process scheme of hub casting is carried out by analyzing the foundry characteristic of hub. The designs of the casting process parameters and pouring and feeding system are completed. The initial condition and boundary conditions and the thermal physical parameters of flow field and temperature field are determined. Then the casting filling and solidification process of computer simulation are carried out. Casting optimizations are carried out by predicting the position, shape and size of shrinkages. Ultimately, the actual casting production verification result is contrasted with the theoretical calculation result.The actual situation of mold filling and solidification process is reflected in the computer simulation, and the possible size and location of shrinkage is predicted. It is found that shrinkage defects are obviously controlled by the getting system of semi-closed bottom and the feeding system of riser combination with the cool iron. The result show that risers are set on the hot spot of the axle hole of hub, cool iron is set down the hot spot of ballast-hole to make it hard set in turn, which can improve the state of hot spot effectively to elimination and control the shrinkage. The hub casting is produced with the optimization of casting process, and the hub casting is detected with ultrasonic and casting quality requirements can be achieved through the production. That is proved that optimization of casting process is effective and feasible with numerical simulation technology.