Simulation Study Of The Upper Bracket And Cone Of Oversize Gyratory Crusher

In order to avoid casting defects such as pore, crack, inclusion, segregation, andshrinkage porosity in actual sand casting production of the key components on the gyratorycrusher. The numerical simulation research was used to simulate and analyze the solidificationcasting process of the gyratory crusher in the production of Shenyang casting and Forging Co.,Ltd. The paper provided an actual casting process and the theoretical direction to thelarge-scale gyratory crusher practical production.By using the ProE software to build the three-dimensional model of the upper bracket ofgyratory crusher, the casting technology on basis of the structural features of the upper bracketwas design. The ProCAST simulation software was used to simulate and analyze the flow fieldand temperature field of the upper bracket of the gyratory crusher. And the critical solidfraction parameter was used to predict the defect area. Meanwhile, the reason of the hot spotslocations related to the shrinkage cavity was analyzed through Niyama criterion. Based onwhich the original casting process was optimized, the results obtained by computer simulationindicated that the optimized casting process keeped to the directional solidification manner.Therefore it was predicted that no shrinkage cavity and porosity can be formed in the casting.On basis of optimizing and simulating the process, the casting was tested in the practicalproduction and obtain the good quality upper bracket.By considering of the cone structure, the Casting process was designed and improved. theProE was used to build the casting process model of the cone, ProCAST was used to simulatethe process of filling and solidification, and also analyze the flow field, temperature field, thesolid fraction and defects distribution. The casting process ensured steady filling andprogressive solidification of the cone. And it was predicted that no shrinkage cavity andporosity in the cone, the casting process design was reasonable take through the verification ofNiyama criterion.