Numerical Simulation On Casting Process For Al Alloy Two-body Seating Coat And Al Alloy Conductor

Al alloy two-body seating coat is a part of new electric locomotive, and Al alloy conductor is one of the important components on high voltage distribution equipment. For structure reasons, Two-body seating coat and Al alloy conductor are easy to turn up defects in key areas, such as shrinkage, porosity shrinkage. To ensure that the two-body seating coat's strength and Al alloy conductor's electric conductivity, get no defect casting, and improve production efficiency, it is necessary to simulate the casting process for casting process optimization.Based on Al alloy two-body seating coat and Al alloy conductor,The article reviews the basic theory of numerical simulation and casting simulation software ProCAST. Combined with the knowledge of casting technology, Al alloy two-body seating coat is designed two schemes, one is opening-up casting method, the other is opening-down casting method; Al alloy conductor has seven schemes (three ideas), including resettlement dark riser, additional external cold iron and change structure.The simulation results of Al alloy two-body seating coat show that:On opening-up casting method, when set proper size riser on it inner under-edge, casting shrinkage will disappear, get the technology product yield about 45%. And on opening-down casting method, through set a cold iron in the middle of the thick, and suit dark riser and insulation riser, The feeding problem can be solved effectively, get the technology product yield about 39.9%. Through the optimization scheme, to optimize the opening-down casting method, when the insulation riser sets to 80mm, casting head 90mm, the casting can get more effective feeding, the technology product yield comes up to 48.6%.The simulation results of Al alloy conductor show that:the idea of set cold iron and dark riser under the sand casting is feasible, in structural change, sand casting and metal casting are both taken very good guarantee, the technology product yield all at 74% above. Through comparing the characteristics of each scheme, choose the structural change scheme of sand casting and metal casting to optimize. the best optimization scheme is metal casting, the selection is straight Cooling channel pipe length 45mm and bent Cooling channel pipe length 55mm.Through the use of Pro/E and ProCAST, sum up the improvement methods that using Pro/E draws centredgrating and ProCAST draws volume meshing, then make the casting simulation process more smoothly. Through the simulation, Two schemes of Al alloy two-body seating coat both have good effect, also well proved in practical production; Four of seven schemes are success in Al alloy conductor, especially the success of structural change scheme, will be more beneficial for the actual production.