Numerical Simulation On Casting Process For Al Alloy Curved Arm Box

Al alloy curved arm box is one of the parts of high voltage circuit breaker.Because of its working in high pressure environment and stringent technical requirements,the casting can not have any defects shrinkage after forming. Al alloy curved arm box is thick in the bottom of the flange in the manufacturing and it will be defected. The numerical simulation by using pre-simulation analysis of the parts can be defect early to judge the situation, so that the process improvement can be completed quickly and accurately.In this paper, SF6 circuit breaker box ZL101A metal casting arm for the study.After understanding of its technical requirements of the case were Abduction arm and develop a case structure analysis of two sets of casting process, namely, flange disk down to casting and flange up to casting. The box under the arm may be in the bottom flange, the top of curved arm box and lever arm generated at the casting defects of this article discussed the nature of the defects in the cast iron under the possibility of internal cold and the internal interface of the cold iron castings combined impact.There are two casting methods in the test of cold, top pouring and bottom pouring. First of all programs in the top pouring I use the ProCAST software to analysis cold iron castings and internal interface conditions and verified the casting experiment through the aluminum. The analysis shows that:in the sand casting,Φ50 andΦ8 aluminum alloy are metallurgical bond; in the metal mold casting,Φ50 andΦ4 aluminum alloy are metallurgical bond. Note the end of the program to add aluminum castings ranging in internal diameter of the cold iron, ProCAST software simulation through the internal diameter of these ranges chill casting of aluminum, the analysis shows:Φ50 andΦ30 aluminum castings to add the internal cold ironΦ40 andΦ20 aluminum alloy castings to add iron to eliminate the internal cold aluminum casting Shrinkage may have to replace the riser set, in the case of the internal structure to ensure that the process easier. Finally, pouring down through the flange and flange up two different casting processes carried out on the Po-arm casting process simulation box.ProCAST numerical simulation software through pouring up and pouring down casting process simulation, analysising each process to be reasonable and set within the cold iron casting defects after the improvement. Need to follow these steps: three-dimensional solid modeling, assembly, mesh, parameters, result analysis. Through the analysis shows that:there is no upward casting defects when the flange is up, but need to be placed two out of riser and core sand needs to hang up first, so the installation is more complicated. But the design of flange down pouring process is simple, sand core positioning it directly into the cavity flange and side wall around a shrinkage contacts generated through the internal cold iron set to the defects disappear, get good castings. By simulating the process of flange up and down to add the cold cast iron castings the parts are perfect, and the casting flange down more easily manufactured.