In recent years, in order to improve the level of digital manufacturing technology in the traditional casting industry, a lot of research and development have been carried out on the numerical simulation technology of casting process at home and abroad, and a number of scientific research achievements have been developed. The most famous commercialized software systems of simulation technology include mag-masoft in Germany, ProCAST in the United States (now acquired by ESI group in France), FLOW-3D and so on. Casting computer simulation technology is developing and growing. It has stepped out of the academic laboratory and continuously entered the front line of casting production. In 2015, our company invested heavily in ProCAST simulation software and began to promote the research and application of casting CAE simulation technology.
(1) The composition of molten iron developed fluctuates greatly. The products include nodular cast iron, ordinary cast iron and steel making. The composition of nodular cast iron is Si = 1.00% ~ 1.60%, Mn = 0.40% ~ 0.80%, s = 0.02% ~ 0.045%, P = 0.03% ~ 0.08%. Among them, 8583 tons of nodular cast iron meet the national standard GB / T 1412-2005, with a success rate of 83.80%. 7473 tons of products fully meet the additional requirements of the machine repair factory, with a success rate of 72.97%. This development is basically successful.
(2) Under the existing raw material conditions of Masteel, it is possible to produce nodular cast iron by selecting Aoshan magnetite powder, iron oxide scale and luobuhe iron ore powder as sintered iron raw materials. The P content of the product must comply with the national standard GB / T 1412-2005. In the future, for large-scale industrial production, the key is to ensure the supply of raw materials such as iron oxide scale and steel chips.
(3) It is necessary to add silica in smelting nodular cast iron. Its particle size is 25 ~ 50 mm and its dosage is 40 ~ 50 kg / T.
(4) According to the blast furnace charge structure of this smelting, the binary basicity of sinter should be 1.65 ± 0.15, and the carbon content should be 5%.
(5) The economic benefit is remarkable. The product cost of this development is about 2150 yuan / T, which is 650 yuan / t lower than the external purchase price of the company and 200 yuan / t lower than the transportation cost. The total cost saved for the company is more than 7.29 million yuan. In addition, the economic and social benefits of ductile iron castings are more considerable.
Aiming at the problem of oil leakage in the seal oil pressure detection of hub components of a tracked vehicle, the casting process scheme, pouring and solidification process of steel castings are numerically simulated by using the analysis technology of Pro cast simulation software, and the main distribution areas of internal defects of hub steel castings are accurately predicted. At the same time, the casting process scheme is optimized, and the optimized casting process scheme is simulated and verified, A reasonable casting process scheme was explored and the casting defects of wheel hub steel castings were solved.