Foundry Process Design And Optimization Of Valve Body Series Of Pneumatic Components

In this paper,the casting process plan and filling process parameters of the valve body series castings of pneumatic components were studied.Low pressure casting technology has been widely used in the field of precision casting.The castings produced by this technology have better comprehensive mechanical properties and dense structure than the ordinary gravity casting.It is suitable for producing some castings with complex structure and shape and excellent quality.In this project,three castings with similar shapes and structures,but different sizes are named FT-1,FT-2and FT-3 respectively,and their structures are analyzed.It is determined that the castings can be produced by casting method.The valve body series castings of pneumatic components require high dimensional accuracy,high surface finish and dense internal structure.Therefore,according to the quality requirements and structural characteristics of the valve body castings of pneumatic components,the metal mold low-pressure casting method is adopted for production.According to the structural characteristics of FT-1,FT-2 and FT-3 castings,a reasonable casting process plan is designed,and a low-pressure casting filling process is designed based on the principle of low-pressure casting technology.At the same time,the casting process of FT-1,FT-2and FT-3 castings is simulated by numerical simulation technology.In order to improve the accuracy of numerical simulation,the interface heat transfer coefficient between Al-Si alloy castings and mold is calculated by inverse heat conduction method.The interface heat transfer coefficient between Al-Si alloy and metal mold is16247.2-2603.14W/m~2K,and the interface heat transfer coefficient between Al-Si alloy and water-cooled mold is 22791.2-3512.2W/m~2K.In order to improve the accuracy of the calculation,the results of the interface heat transfer coefficient are used to simulate the solidification process of the valve body castings.Then,the casting process of initial design of different castings is simulated,and the casting process is optimized according to the simulation results.According to the optimization of the casting process for the actual casting production verification,the optimization of the casting process can produce qualified castings and casting numerical simulation accuracy.According to the optimized filling process parameters of FT-1,FT-2 and FT-3 castings,the relationship between the characteristics of the castings and the filling process parameters of the castings was determined by SPSS software.According to this relationship,the calculation formulas of process parameters of different castings are determined,and the method of determining the filling process parameters of low pressure casting of valve body series castings of pneumatic components is provided.The low-pressure casting process plan of FT-1,FT-2 and FT-3 castings has been determined through the research of this subject,which provides sufficient theoretical basis for the design of low-pressure casting filling process parameters of the whole series of castings,and has great significance for the actual production of castings.