Casting forming process

The foundry industry is an old and very important traditional industry. It plays an irreplaceable role in both developed and developing countries. According to the structural characteristics, technical requirements, production batch and production conditions of the casting parts, the process of determining the casting plan and process parameters, drawing the casting process diagram, weaving the process card and other technical documents is the first casting process design before casting production. Casting process design is the basic component and key link of casting production. The quality of casting process design plays a vital role in casting quality, productivity and cost.

At present, the foundry industry basically adopts the traditional process design method, and the process modification is frequent, which requires a lot of manpower and material resources, resulting in high development costs. Even if the quality of the products produced meets the user’s requirements, it is impossible to verify whether the process is the most reasonable process.

From the traditional flow chart, it can be seen that the traditional product development is a trial-production judgment method. When process improvement is needed, the process test shall be carried out again. In this way, the final mature and reasonable process can be obtained, and the process of quality improvement is also the same. Its characteristics of high consumption, high cost, low efficiency and low production rate are extremely unfavorable to enterprises in the fierce market competition. Main defects caused by unreasonable process design include):

(1) The casting has shrinkage cavity and porosity defects, which exceed the acceptable range of users.

(2) The surface defects such as slag inclusion and sand filling caused by the unstable flow of molten iron exceed the range allowed by the user.

(3) The material properties of castings can not meet the user’s requirements. In view of the above, a stable and reliable process must be established in the product development stage to eliminate these defects to ensure reliable product quality and low scrap rate after batch production. The research and development of casting CAE makes the application of computer simulation of casting filling and solidification process in engineering possible and practical.

One of the important development trends of the advanced production technology in China is to carry out a new round of process design optimization, screen trial casting and process verification. The process design is from empirical judgment to quantitative analysis. Computer numerical simulation is an important method and way to achieve this goal, and is an important sign to make the process research of the casting industry from qualitative to quantitative and from experience to science. At present, the research and development direction of casting forming technology in the world is the key casting technology of oversize castings in major projects, the precision casting forming technology, and the computer simulation to gradually replace the traditional empirical research method. Using computer die drawing technology can shorten the trial production cycle by 40%, reduce the production cost by 30% and improve the material utilization rate by 25%. The in-depth research on the computer numerical simulation of the casting process will provide the basic data and theoretical basis for the optimization design of the casting process. Through the computer simulation of the casting process, the casting defects under various parameters will be analyzed to determine the process parameters, optimize the process plan, and finally achieve the goal of high quality, high efficiency, low consumption, and clean, which will certainly produce considerable economic and social benefits.

The research contents and methods are of popularization and application, providing reference basis for further research of relevant contents, and also of important practical significance and practical value for practical production and application.

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