Development And Application Of 3D Casting Process Aided Design System Based On UG/KF

In casting production,reasonable process design is the key to ensuring the quality of castings.Due to the complex design process of casting process,it is necessary to consult relevant manuals,involving many formula calculations,and the drawing process is cumbersome and the workload is large,so most of the casting process design relies on the experience of designers.Three-dimensional CAD software has been widely used in the field of casting,although the use of interactive functions provided by software can complete the process design,but in the design process of some empirical and repetitive work has not been automated,still need designers to repeatedly design their own design,so that the efficiency of product design is reduced,so it is urgent to develop casting process auxiliary design system in three-dimensional CAD software.This paper takes Siemens’ UG10.0 software as the secondary development platform,based on the UG/Menu Script and UG/KF(knowledge fusion)language provided by the software,embeds some existing casting process design methods into the software,develops a three-dimensional casting process auxiliary design system,and uses the system to design the casting process,uses Pro CAST finite element numerical simulation software to analyze the process,and finally conducts casting process experiments according to the simulation results.The main research content of this article is as follows:(1)The three-dimensional casting process auxiliary design system is divided into5 modules,namely information acquisition module,riser design module,sprue design module,sprue cup design module and subsidy design module.Among them,the information acquisition module has casting basic information acquisition tool and area modulus acquisition tool;the riser design module has hotspot circle proportional method riser,modulus method riser and user-defined riser;the gate design module has pouring type design and sprue section design;the gate cup design module has spedge cup design tool;the subsidy design module has a rolling circle design subsidy tool and a horizontal subsidy design tool.(2)Taking the flywheel casting as an example,the gating design module of the auxiliary system is used to design the side top injection semi-closed gating system for the flywheel part,the riser design module is used to design the hotspot circle proportional method riser for the flywheel;the sprue cup design module is used to design the basin-shaped sprue cup;and the information acquisition module is used to check the yield of the process.Comparing the traditional UG operation with the auxiliary system operation,the auxiliary system operation is more convenient and the design efficiency is significantly higher.(3)The use of ProCAST software to establish a finite element model for the flywheel parts,the casting filling,solidification process and defects analysis,analysis results are displayed: the filling process is gentle and stable,no turbulence,gas wrapping,insufficient pouring and other defects;the solidification process from the heat dissipation area of the area began to solidify,the whole process riser to the casting to make up for the shrinkage;a small number of shrinkage defects are located inside the casting,the hot crack is mainly located at the root of the riser,the quality of the casting has no impact,to meet the technical requirements.(4)The actual casting process experiments of the flywheel parts,the casting conditions are basically the same as the numerical simulation conditions,the results show that the top of the riser is contracted,indicating that the riser has played a contraction effect on the casting,and the hot crack is located at the root of the riser,which is consistent with the simulation results,and the surface quality of the casting is good.