Steel Casting Technology Analysis And Optimization Based On Numerical Simulation

At present, the most competitive research method of foundry technology is numerical simulation on mold filling and solidification process. This process is helpful to predict defects, optimize technologic parameters, insure the casting quality, shorten the trial-produce cycle and lower the cost.With the development of CAD/CAE software, more and more companies apply them to production process. Co-operating with Ningbo Dongdian Electric Power Equipment CO., LTD, this paper, based on Solid Edge and ProCAST, does the research work as follows:There is a data transform problem between Solid Edge and ProCAST software, which is an obstacle to the numerical simulation. One of the research is to find a valid mode to solve this problem.According to the real needs of the company, the process of numerical simulation on trailer big end is conducted. The results prove the parameters are correct through comparing with the trial product. Then the technology is optimized from gating and feeding system.Top and bottom gating system of KU-1004 casting, which are provided by the company, are simulated in this paper. Their competitive results, which can be as the reference and gist, show which one is better and where needs to be optimized.This paper puts forward the model-containing concept for the first time and resolves the data transform problem of complex models between Solid Edge and ProCAST by using a technical way of "whole - parted - whole". Optimized technology avoids generating defects in the casting body and has been applied in the company. The gist of selecting technology helps to establish the parameters of similar castings. It is proved that numerical simulation can solve technologic problem and create huge economy benefits, which means a lot to the company.