Process Design And Optimization Of The Front Frame Of GE300 Mine Crusher

The crusher front frame is used in the process of mineral crushing,which mainly plays a blocking role in the crushed materials.The study in this thesis originates from the export part of a jaw crusher front frame produced by a certain company,but its casting process still has certain casting defects in the actual production,such as hot cracking,shrinkage porosity,porosity and so on,facing the problem of low yield.How to effectively predict the types and positions of possible defects and adjust product quality is an urgent problem to be solved in the production of high quality castings.In this thesis,the sand mold casting process of the front frame of the crusher is taken as the research object,and the Pro CAST finite element simulation technology is used to predict the types and positions of the defects that may appear in the casting process,so as to guide the optimization of the casting process and reduce the production cost,which has a certain degree of theoretical and practical significance.Firstly,the structure of the front frame of the crusher is analyzed.The front frame is a small and medium-sized cast steel part with complex structure.The reinforcement bars are set in the cavity for support,and there is a high possibility of hot joint defects at the junction of the reinforcement plates on the important stress surface.The initial process adopts the intermediate injection,the inner runner is located at the parting of the casting,the riser is placed near the hot section on the large plane of the casting,and the cold iron is arranged along the casting reinforcement plate.The optimized process adopts the step gating system,increases the number of riser at the plane hot section,appropriately reduces the size of riser,and the modified size of riser is 230 mm.By simulating the filling process and solidification process of the optimized casting process,the secondary optimization of the process was carried out until the optimal casting process was determined.In the optimal casting process,the rise of liquid steel in the cavity tended to be stable,and the maximum filling speed changed from3m/s to 1.8m/s.The shrinkage cavity and porosity defect is transferred from the inside of the casting to the riser and the range of machining allowance,and the shrinkage volume eventually becomes 8.6cm3.The maximum value of equivalent stress was improved from 390 Mpa before process optimization to 90 Mpa.It is determined that the optimal casting process is symmetrical bottom casting system,and sufficient riser feeding is set in the large plane hot spot of the casting.Finally,through the actual production and casting inspection,it is concluded that the product quality can be improved to a certain extent to ensure the yield of good products,which provides a reference scheme for the casting process design and optimization of steel castings.