Simulation Research For Forming Process Of WJ-8Iron Backing Plate

In this article, WJ-8iron plate is chosen for the research.The three-dimensional modeling is made by using the Pro-Engineer and the simulation study of the filling and solidification process under the original condition is done by using the ProCAST.After that,the temperature field, freezing field and real-filling status of the casting can be got.Also the shrinkage porosity defect distribution can be predicted and the cratering rate is0.732.According to the freezing field and the real-filling status,the cause of the shrinkage porosity can be analyzed and a process improvement program has come out:rise the pouring temperature from1350℃to1400℃,shorten the length of the ingates from60mm to30mm,don’t change the base area of the riser and rise the height of the riser from70mm to110mm.Then the simulation study under the improved process has been done and the cratering rate is0.725.The quality of the casting improves a little.Redesign the cross-sectional area of the ingates,the runner and the sprue in the gating system.Three kinds of pouring ways has been designed:top-pouring,bottom-pouring and the lower third pouring.Do the simulation study when the pouring temperature is1350℃,the casting speed is300mm/s and the temperature of the sand mold is30℃.The cratering rates are:0.711,0.739,0.724.By comparing the cratering rate,the top-pouring way is the best.A research of the pouring temperature,the casting speed and the temperature of the sand mold to the quality of the casting has been made by using the orthogonal test.The quality of the casting is the highest when the pouring temperature is1350℃,the casting speed is300mm/s and the temperature of the sand mold is30℃.During the sand casting process,the casting speed influences the quality of the casting mostly,then comes to the pouring temperature and the temperature of the sand mold has little effect on the quality of casting.