Modified Ring Hammer Manufacturing Process And Lost Foam Casting Numerical Simulation

According to statistics, economic losses caused by wear of machinery andequipment parts in industrial developed country is about6%of the grossnational product. Therefore, solving the problem of wear and extend the servicelife of mechanical equipment and components become the first issue to considerin design, manufacturing and utilizing of all kinds of mechanical equipment. Inthis paper，casting process of crusher hammer ring was modified., a new type ofmodified high manganese steel and a new lost foam casting process weredeveloped.Numerical simulation of the ring hammer casting process has incomparableadvantages over field test. Simulation can not only effectively reduce materialloss and energy consumption in the process of casting, and can also greatlyshorten the test period, save time and effort.Applying the modified high manganese steel and a new casting processdesigned，numerical simulation of lost foam casting process of ring hammer wascarried out using software ProCAST. The thermal physical parameters of thering hammer material was measured using Jmatpro software，then input intosoftware ProCAST. In the LostFoam module of ProCAST, filling andsolidification process of crusher hammer ring was observed, different pouringtemperature, casting speed, the characteristics of the filling process andsolidification process were analyzed, and a improved process is put forward.The reason of defects such as shrinkage cavity, shrinkage and porositygenerated during the casting process was analyzed, possible positions liable tooccur is predicted, and therefore measurements can be taken to prevent defects,and rational and effective casting process can be designed. After completesolidification of hammer ring, shrinkage mainly appeared at the casting ingate,temperature far away from the ingate is lower, and will solidified first, partstemperature close to the location of runner is higher, the solidification speed isslow, shrinkage cavity defects can’t be completly refilled, and defects such as shrinkage is easily to form.