Process Optimization And Simulation Programs On Transmission Housing Of Forklift With Lost Foam Cast

Due to the presence of foam makes the lost foam casting difference from the traditional casting. It is very difficult to control the casting defects such as LFC flow field, temperature field, including filling capabilities, so the casting defectsis very difficult to control. By use the computer simulation techniques could directly observed the filling and solidification of the casting process, and analyze the reasons of the casting defects, and optimizing the casting process parameters to improve the quality of the casting.Casting simulation the three-dimensional modeling by use the UG in the paper and simulated by ProCAST simulation software, for the coMPany of gray cast iron as the material body is a mechanical gearbox LFC and improvement.The company produces mechanical gearbox castings at the bottom, middle and corner flange shrinkage porosity defects are present, can not meet the quality requirements. In order to identify the causes of defects by using ProCAST filling and solidification simulation software to simulate the casting process, and to analyze the process results; in the process parameter settings, create a new database casting materials; setting reasonable initial, boundary conditions of the heat transfer coefficient and substituted coatings. It is found antes style gating system does not meet the production requirements in result, the interior of the casting molten filling appears turbulent, and can not satisfy the principle of solidification, It can not be achieved by graphite cast their expansion and runner feeding, to predict the location of shrinkage porosity defects and verified by the actual production and found basically the same, and thus illustrate the accuracy of simulation.To improve the original process by improve the bottom gating changed stepwise manner, pouring temperature of1480℃, the negative pressure is-0.06MPa, the use of a box of a production, and set reasonable cylindrical riser on casting. To simulate the casting of crafts improved, it can be seen from the result of the molten filling promote more stable, not easy to produce turbulence, thus avoiding slag, porosity defects; On the other hand, riser solidification time is more than casting’s, you can take on the casting feeding, reduce shrinkage porosity defects. After process improvements, found at the bottom of the casting shrinkage porosity defects has been greatly reduced, and only a small number of distributed processing defects in the vicinity of the hole and not the rest shrinkage porosity defects are in the riser inside or eliminated. Verified by actual discovery consistent with the simulation results, the casting quality can be achieved the using requirements, and verify the accuracy of the simulation software ProCAST.