Research And Implementation Of Virtual Special Casting Process

In recent years,due to the advantages of high efficiency production,high quality castings and high level of automation,special casting has been widely used.Since the difficulty of designing casting process,in actual application,the numerical simulation of casting is used to simulate the filling and solidification process of molten metal,which can predict defects and provide scientific guidance for process planning.However,numerical simulation is too time-consuming and complex to obtain the result in real time.Therefore,most of existing virtual casting systems can only provide the function of designing and operating.Aiming at the above problems,this paper focuses on studying the real-time defects prediction approach and developing a virtual special casting system based on the virtual reality technology.The main contents are as follow:(1)Studied the simulation of the filling and solidification process and predicted defects by analyzing the result of simulation in the ProCAST software.Referred to actual production cases,the high pressure die casting(HPDC)and the centrifugal casting(CC)are selected for numerical simulation experiments.According to the experimental results,quantitatively analyzed the influence of casting parameters on casting defects.(2)Studied the real-time defect prediction approach.According to the studied of existing defect prediction approach and numerical prediction approach,a artificial neural network(ANN)based defects prediction approach was proposed.Built the Back Propagtion Neural Network(BPNN)and Radial Basis Function Neural Network(RBFNN)for each defect.According to the result of training fitting experiment and actual prediction experiment,the BPNN was selected as the basic algorithm of the defect prediction approach.(3)Developed a virtual special casting system(VSCS).Analyzed the requirements of developing VSCS,built the software and hardware platform,and designed the structure of system.Based on the Unity software,developing the core content of VSCS,such as process scene,user interfaces and key functions.(4)Took the training experiment of HPDC and CC as examples,conducted the special casting training test and usage questionnaire to evaluate the effect of teaching and the defect prediction approach in virtual casting system.The experimental results showed that the system can realize the functions of teaching and training,provide user with complete process flow,and improve the use efficiency of VSCS,without causing a burden on system.