The Prediction And Control Of Deformation Of ZL205A Large Shell Cylindrical Castings

In this paper, parts of large thin-walled cylindrical shell with ZL205A alloywere studied. The deformation during the solidification of casting and quenchingafter the solidification were simulated by commercial simulation software ProCASTand heat treatment modules in SYSWELD simulation software, and rules in thedeformation were achieved. Based on the rules, the deformation was adjusted byincreasing the height of the casting and an additional reinforcement ribs in theinterior of the casting method.The parameters of thermal properties for ZL205A alloy in the solid-liquidphase temperature range and below the solidus were obtained by testing them in theheat solidus range and calculating them with the materials database in the softwareProCAST. The experimental values of the line expansion under300℃matchedgreatly with the calculated ones.By analysing the deformation of the cylindrical shell casting solidificationprocess of the actual production of the factory. Considering the deformation ofcylindrical shell casting occurs mainly in a radial direction, the deformation of thecasting inside is much larger than the inner. The walls’ thickness of casting in thedeformation process will be reduced due to hinder of core; Casting’s deformation ina height direction occurs mainly in the early solidification due to the differentamount of radial deformation caused by the different heights, but with the castingcooled in the flask, the radial deformation of the casting with different heightsbecome consistent, and thus the casting deformation in the height direction isreduced.On the basis of predicting the deformation of the cylindrical, this paper havetaken to increase the height of the shell casting cylindrical inner shell castingsstrengthen tendons and set triangular structure inside the casting stretch andhexagonal structure reinforcement approach to casting solidification processdeformation control. Studies have shown that increasing the height of the innercylindrical shell casting method can reduce the deformation of the cylindrical shellcasting, it is effective to prevent the casting deformating during solidification;different stretch control cylindrical shell casting’s deformation aspects: the use ofhexagonal cross-section castings beam reinforcement structure radial deformationbetter than the triangular reinforcement structure control.By using simulation software’s module of SYSWELD to simulate the heattreatment process of the cylindrical shell casting found that the inner wall stiffener rib becomes heighter, the greater deformation of the cylindrical shell casting; Forreinforcement in the form of hexagon, By inhibiting the top contractionis in the Ydirection to reduce the diameter difference of upper and lower, and in the Xdirection by promoting the contraction of the upper to reduce the diameterdifference of upper and lower, so that casting’s deformation on the upper and lowertends oval;However, reinforcement in the form of triangular make casting’sdeformation on the upper and lower tends circular. Triangular reinforcementstructure control in the opinion of the casting deformation during heat treatment isbetter than the hexagonal structure reinforcement.