The Quality Forecast Of Larger Steel Casting Based On The Numerical Simulation Method

Solidifying process is very important for the quality of steel castings. All kinds of disfigurements, such as shrinkage, porosity and distortions and so on, come into being in the solidifying process or relate closely to it. How to change the liquid metal temperature, how to solidify liquid metal and how to form disfigurements are blind and invisible for the foundry workers after the liquid metal flows into the molds. How to calculate and trace out the solidifying process in order to optimize design to become the perfect technical documents is the main task of numerical simulation, which can cost less materials and manpower to make higher quality castings. Based on the numerical simulation, a study on forecasting the quality of larger steel castings is executed in this paper. The disfigurements often appeared, such as shrinkage, porosity and distortions are forecast by the numerical simulation to optimize the technology and reduce the cost. Through analyzing the temperature field and stress field of typical steel castings some casting parameters as modulus, the distance of feeding head, cold iron are validated and modified, which is in accordance with the production-lines. In this study the distortion resistant quantity and tie piece are decided on by analyzing the stress field and the large numbers of experimental data ensuring the dimension of castings, for the distortions of lower rims and vanes are likely to occur in the solidifying process. The numerical simulation is used in the production-lines by forecasting and researching the typical steel castings, which can eliminate blindness of the technical design, shorten the cycle of new technical design and reduce the cost. The accuracy of technology is improved and the maintenance cost is reduced greatly by computer-aided pre-production. All those are essential to the enterprises because they can increase the economic benefits and the competition.