Lost Foam Casting Process Simulation And Rapid Manufacturing Of Complex Parts

Based on the urgent need of efficiency and clean, green production of our country’s equipment manufacturing industry, aiming at saving energy and reducing consumption, improve resource utilization, in this paper, advanced computer numerical simulation technology, CNC technology were introduced into the traditional high energy consumption, heavy pollution of the foundry industry. The current domestic development method of the complex box-type parts is still mainly use the traditional wooden mold or metal mold molding process. These methods are obviously having certain disadvantages in development cycle, manufacturing precision, processing flexibility and production costs, etc. It is difficult for them to meet the increasingly diverse needs of today’s market.Comprehensive summary of application and exploration of lost foam casting (LFC) simulation technology based on ProCAST was given. The application research of rapid development in LFC process for the typical complex box-type casting parts was conducted and it is significant for the efficient and green development of the similar casting products. The main content of the paper are as follows:Firstly, the application research of LFC process simulation technology is summarized. The important influence factors of LFC process are analyzed in the perspective of basic flow field and temperature field through a group of contrast simulation experiment.Secondly, the design approaches of the process scheme of LFC and the original design were analyzed, and the new process scheme was designed based on the large orifice discharge theory and proportional solidification principle.Thirdly, both the original and several new LFC process schemes of the typical complex box-type parts were analyzed through multiple times’ simulation experiment, and the optimum simulation experimental parameters of the optimum process were determined by orthogonal experiment.At last, in order to verify the designed LFC process for the single and small batch production products, the CNC machining experiment of EPS and LFC pouring experiment were conducted, and the results was actually quite good.