The Application Research Of Computer Simulation And Experimental Design Technology In The Casting Process Design

In recent years, the casting process simulation design has developed into a technology having the enormous value of project application and scientific research, but in our country it has not been applied in the true sense so far.This topic " The applied research of the computer simulation and the experimental design technology in the casting process design" in view of the urgent need for our country's foundry industry development, proposed the "3 stages,9 stairs" new method to achieve the simulation design in casting process for the first time:using simulation softwares+ appling simulation softwares+perfecting simulation results+optimizing the gating system construction+optimizing the size of the gating system construction+optimizing system technological conditions+the scene evolutionary of the simulation optimized process+product technology management documents+product production management documents, and proved its usability through many examples.For the first time this topic proposed the idea "to choose the simulation softwares and make the simulation plan in view of the concrete casting method, the alloy material and the casting defects" and realizes:under the condition of the 6 commonly used casting method, that is, Sand Casting, Lost Foam Casting, High Pressure Die Casting, Investment Casting, Centrifugal Casting, Permanent casting and so on, in view of the material quality and characteristic of cast steel, cast iron, aluminium alloy, copper alloy, magnesium alloy and so on, to choose and use overseas casting simulation softwares such as ProCast, Magmasoft, AnyCasting, Flow-3D and NovaCast and so on and the national Hua Zhu CAE and FT-start in order to solve or prevent the defect problems of compact texture and distortion in 5 category casting namely the shaft tubes class, the shell class, the planking class, the box body class and the assembly classification class.This topic also firstly proposed:The experimental design technology will be applied in the casting gating system construction, the size of gating system construction and in the systemic other casting process conditions to realize the simulation optimization design in the casting process and achieve the aim of simplifying the gating system construction, reducing the gating system weight, and then raising the craft product rate and reducing the production cost; Appling the evolutionary operation and its phase migration principle to the production field to cause the most superior process under the simulation condition to transform into the most superior craft under the actual working condition; Aiming at the concrete product to formulate its technical management document and production management document in order to make the casting foundry to realize the most superior craft through the product technical management document and to constantly realize it through the product production management document (this partial contents had not obtained practical application under industry field condition as a result of time relationship).This topic's research content not only may be helpful to break "the technical bottleneck" of the application in casting process simulation design to choose appropriate casting process CAE software and its module for designing in view of the casting product's characteristic and its quality requirement; but also may satisfy the researchers who conducts the systematic research to the casting process design to further enhance the level; besides those, it may also satisfy the higher requirement in scientific research and be helpful to truly promote our country's research level of casting process simulation design.As a study base of this topic——Hebei Haiyue Wear-resistant Material Science&Technology Co.,Ltd with my teacher and our team, the project "The Lost Foam Casting Process Simulation Design" has attained the North China's significant science and technology research project in 2007. Two graduates of my teacher's went there to work in the simulation laboratory in July 2009. This place becomes the workstation for academician of Chinese Academy of Engineering in Hebei Province in September 2009.