Simulation On Lost Foam Casting Process Of The Water Slag Iron

Lost foam casting(LFC or EPC), as one almost pollution-free production technology, enjoys a bright development future. Recently, Evaporative Pattern Casting technology has found wide applications in cast steel and aluminum alloy, but limited applications in cast irony.To study the application of Lost foam casting simulation technology to cast steel and promote the development of Lost foam casting technology, firstly in this thesis a Lost foam casting process via is introduced which slag iron can be directly used to produce grey iron castings, and the experiment of a metallographic analysis and mechanical property is made on the lost foam grey iron castings that are the products of this process. Secondly, three-dimension models are made on the casting, casting system and riser via Pro-E, and both ProCAST and Visual Environment are used as digital simulation tools for the casting process to make simulative analyses of the metal liquid filling and solidification that takes place in the slag-iron-to-grey- iron-casting process. Thirdly, an exploration is made of digital simulation under the top gating and bottom gating systems, and both simulation and trial-production findings indicate that defects are found in the casting, such as porosity and slag. Finally, to address this problem, improvement plans are put forward, and simulations resuts show that flaws such as shrinkage porosity and slag can be disposed of and functions of the casting are fully met. The following conclusions are drawn: 1.A new method of use water slag iron making grey iron Lost foam casting production has been developed in this paper. To use slag iron to produce gray iron castings shortens production cycle, reduces production cost and enhances productivity. 2.The experiment indicates that gray iron lost foam castings made from slag iron are on par with standard gray iron in terms of metallographic property and mechanical property. 3.A trial-production plan is formulated to use slag iron to directly produce chassis castings(HT150) via ProCAST, one casting simulation software. It can be known from the trial that bottom gating process plan is subject to marked shrinkage porosity easily and top gating process plan is subject to slag. 4.On the basis of the comparison between the ProCast simulation and trial-production plan, a casting process plan is put forward to optimize LFC process. The trial-production shows that step gating process plan constitutes a solution to internal shrinkage porosity for small castings and slag for castings.