The Numerical Simulation Research Of Forming Process Of The Typical Box Casting

Casting CAE technology development and research make application of the casting forming numerical simulation technology in the actual production to become a reality, the image clearly display the change of temperature, speed and the solidification micro structure such as defects during casting process. Analysing the causes of defects, and improve process plan. Combining visualization technology and casting technology to solve the problem of unable to observe changes of molten metal in cavity of traditional casting. The filling and solidification process were simulated of the typical box castings by casting simulation software, so providing basis of making pouring process scheme for box castings in the future.This paper firstly summarizes the research status of numerical simulation technology in the casting forming process, and summarizes the structure characteristics of the box, then uses the software ProCAST to simulate the filling and solidification,and analyse causes of defects and location on the numerical simulation theory. The specific research results are as follows:Firstly simulation and analysis of the preliminary design of different pouring scheme was carried out,it shows the status of the filling and solidification of casting and the change of the velocity field and temperature field.the results show only stepwise gating system filling in good condition, no volume gas and short run, so determining the appropriate casting solution.Then simulating the stepwise gating system about pouring temperature and casting speed, and predicting the location of the defect according to the result of simulation, the results show that different pouring temperature have no obvious effect on the mold filling time, but have significant impact on the solid fraction of internal gate solidification and defects, the optimum pouring temperature is1400℃.Influence on the filling and solidification of different casting speed is different, the results show that the filling time decreases with increasing casting speed, Coagulation time increase of speed increase with the decrease of the first, the most suitable casting speed was6.8kg/s.Analysis the reason of defects which appear in the convex sets and hot section of casting, Increasing the riser size and the quantity, increasing the cold iron, changing rounded corners of casting can effectively control defects, then improve the quality of castings. Studying the influence of the casting filling ability of the multidimensional vibration under the condition of solid-liquid two-phase flow by using the method of coupling EDEM and Fluent.The influence of multidimensional vibration for casting filling time and the sensitivity of the number of particle inspection area to different vibration parameters in the filling process are analyzed. The results show that the maximizing sensitive degree for various factors of the number of particle inspection area is degrees of freedom, frequency of the second, and amplitude of weakest.The number of particle inspection area in the filling process is maximum when degrees of freedom is3, frequency is30Hz and amplitude is0.5mm.