Numerical Simulation And Parameters Optimizing For Casting Process Of EGC2040 Column

With the rapid development of computer graphics, animation simulation and 3D technology, casting numerical simulation technology has been greatly developed.Casting numerical simulation can effectively reduce the production cost and shorten the production period, which has been applied to the actual production in more and more foundry enterprises.In this paper, the casting process and casting parameters have been determined on basis of considerations of the bed shape, size and the technical requirements. Also,the casting filling and solidification process, as well as the variations of the filling rate and the solidification rate with filling time have been simulated by Anycasting software. The location and orientation of defects existing in the casting have been analyzed according to the Retained Melt Modulus. An orthogonal experiment with the consideration of the three factors including pouring temperature, filling velocity and cold iron thickness have been conducted in order to optimize the process parameters.The results showed that the filling time and the fully solidification time were90.85 s and 3609 s respectively in case of that the pouring temperature was 1350℃ and the casting speed was 0.9m/s. Simulation profile revealed that the final solidification region would not be feed fully, as a result, the shrinkage porosity could not occur. To optimize the original casting process, the diameter of the riser is increased from60 mm to 80 mm. As a result, the solidification rate of the riser is lower than that in the casting, and the original similar casting defects could not be found in the followed simulation. According to the results of orthogonal experiment, the pouring temperature is the predominant influential factor affecting the quality of the casting comparing with the pouring casting speed and the thickness of cold iron. Based on the optimized parameters, such as the filling temperature of 1380℃, the filling velocity of 0.8m/s and the cold iron thickness of 70 mm, we got the bed casting without any defects.