The traditional process tooling design is carried out for the bracket steel castings of a certain construction machinery. According to the designed process drawing and tooling drawing, the enterprise carries out outsourcing mold manufacturing and product trial production. The results show that the product has shrinkage cavity and porosity defects.
After investigating the defects and rechecking the process, the process and tooling of steel castings were adjusted, and the shrinkage cavity and porosity defects were finally eliminated. Facts have proved that the design completed under the guidance of reference books such as casting process manual needs further adjustment and improvement.
Using the method of example verification, the molds and products are manufactured according to the designed product process, the steel castings are subject to radiographic flaw detection, the pores of the casting defect parts are confirmed, the original process is simulated by Huazhu CAE, the causes of casting defects are analyzed according to the casting defects, and the countermeasures are formulated respectively. Through process improvement, qualified steel castings have been produced.
It can be seen that only relying on reference books such as process design manual for process design can not ensure the design of perfect casting process, and targeted design needs to be carried out according to the structure of steel castings.
According to the design examples and design experience, the improvement suggestions of casting process design are put forward in order to improve the level of casting process design and better guide the engineering practice.