Study On The Cast Process And FEM Numerical Simulation Of Rotary Table

Boring machine is a large modern machine, which used exclusively for underground tunnel dug straight.Roadheader is one of the indispensable equipment in coal industry.Rotary table is an important component of TBM machine, which is the key part for connectingthe chassis and the cutting arm.By rotary table and swing cylinder consist of the cutting mechanism system can finish a variety of movements.Rotary table bears all cutting resistance and resistance moment the working condition, thereliability and stability of rotary table is directly related to the whole machine life, therefore, it is necessary to qualify the quality of the rotary table.Because of the rotary table is the whole cast and casting quality standards is quiet low. In order to optimize the proper casting model, this thesis introduces numerical simulation technique. Apply ing the numerical simulation to simulate the casting filling and solidification process,predict in advance of casting defects. By casting process analysis to determine whether thecasting structure is reasonable and castings process parameters is reasonable.At the same time, casting process parameters and casting structure can be improved by thesimulation technique. It is also an important way to access to few defects or high quality castingcomponent. The simulation technique also can shorten the production cycle and reduce costs.In this paper, EBZ160 type rotary table, for example, according to the structural characteristics and the thickness of the case castings, pouring riser system design. The number of the gate setare at 4 and 6, respectively, the number of risers are 6 and 8.Based on the same casting production method to simulate four different casting model by numerical simulation software ProCAST of filling solidification respectively. Comparing to the results, the bestprocess parameter are 6 risers and 6 runner. Because of mold filling is stable, good flowability ofmolten metal and casting obtained shrinkage area is also minimal in this process parameter.In experiment of practical casting, trying to do 8 risers and 6 runners, and 6 risers and 6 runners two different plans to cast. By ultrasonic testing after casting those two plan, the results show 6risers and 6 runners has few defects. So this result verify the simulation result.