Research On High Frequency And Multidimensional Vibration Casting Of Gear Rack Casting

In order to improve the mechanical properties of the gear rail casting of shearer and ensure the smooth progress of coal mining,it is necessary to conduct in-depth analysis of the casting process of the gear rail casting to find the optimal casting process plan.In this paper,the casting process of alloy steel gear rail casting is simulated by ProCAST software.Through the analysis of the filling and solidification process of the gear rail casting,the position of shrinkage cavity is predicted.Based on TRIZ theory,this paper analyzes the cause of the defect of the gear rail casting,and puts forward the optimization plan of the technology of the gear rail casting-inclined pouring technology plan by using the object field model innovation solution tool,and explains the molding process of the inclined pouring plan,and designs the auxiliary positioning device which is convenient to fix the gate bar.Using ProCAST software to simulate the optimized inclined pouring process,the results show that the scheme can keep the increasing temperature gradient during the solidification process,effectively promote the sequential solidification of the tooth rail casting,improve the structure compactness,obviously improve the shrinkage porosity,and reduce the shrinkage porosity from 2.2%to 0.052%.At the same time,different pouring speed and pouring temperature are set on the basis of inclined pouring.The influence of pouring temperature and pouring speed on the casting process of alloy steel gear rail was studied by analyzing the temperature field and flow field during pouring.When the pouring temperature is 1560?-1580? and the pouring speed is 9.5kg/s,the casting performance is the best.Finally,the standard spiral sample is designed,and the discrete element software is used to simulate the filling flow length of the alloy steel in the spiral sample,and the effect of multi-dimensional high-frequency vibration on the fluidity of the alloy steel is investigated.Through the orthogonal experiment,range analysis and variance analysis are used to analyze the influence of different vibration factors on the fluidity of alloy steel filling.The results show that the effect of vibration during pouring can effectively improve the filling flow performance of alloy steel.When the vibration degree of freedom is X-Y-Z,the vibration frequency is 45Hz and the amplitude is 0.45mm,the filling flow effect is the best.Based on the inclined pouring process of the gear rail casting,the optimal vibration parameters are simulated and verified.The results show that the filling flow distance of the liquid metal is increased from 149mm to 720mm compared with that of the casting without vibration,and the filling effect is significantly improved.A casting model for rack rail castings was produced,and the filling flow experiment was verified on a self-made electromagnetic vibration test bench.The experimental results were basically consistent with the discrete element software simulation results.Figure[63]table[26]reference[91]...