The saddle is a key component connecting the suspension and frame. Due to the newly developed saddle being a cast product, its large size, complex structure, and thin wall easily lead to problems such as shrinkage porosity and shrinkage defects during the production process. Casting simulation is a technology that uses simulation software to simulate and analyze the filling and solidification process of castings. By verifying or modifying the casting process through simulation software, it can significantly reduce the occurrence of defects, shorten the production cycle, improve product quality, reduce costs and energy consumption. Tang Geng et al. optimized the process parameters of aluminum alloy die-casting parts through neural network and genetic algorithm. Under the optimal process parameters, the solidification time of the die-casting parts was reduced, the forming quality was effectively improved, and the probability of shrinkage porosity and shrinkage defects was reduced.
Zhu Huiming et al. analyzed the flow field and temperature field of the brake caliper using the MAGMASOFT software, and obtained the optimal casting process plan using the orthogonal test method. The experiment showed that the results of this plan did not show shrinkage porosity or shrinkage cavities. You Jin et al. adopted a process optimization method that combines grey correlation degree and response surface methodology, with the goal of reducing the maximum thinning rate. They used Dynaform software to simulate and obtain the optimal process parameter combination, providing assistance for the actual production of heat dissipation shell castings. Chen Chuanchuan et al. applied genetic algorithm to optimize the differential pressure casting process of aluminum alloy steering knuckles, using solidification time, secondary dendrite spacing, and shrinkage defects as quality indicators to obtain the optimal process parameter combination. The pouring temperature is 690 C, the upper mold temperature is 320 C, and the lower mold temperature is 350 C. Verify the reliability of the optimal process parameter combination through numerical simulation analysis. Zhang Mengqi et al. conducted casting process optimization for ductile iron automotive wheel hub brackets, using MAGMASOFT software to predict the location of shrinkage porosity and porosity defects. By adding cold iron, defects in the castings can be effectively eliminated.
Taking the saddle of a large thin-walled casting as the research object, an initial pouring process plan is designed. The filling and solidification process of the casting is numerically simulated using AnyCasting simulation software, and the location of shrinkage porosity and shrinkage defects is predicted and verified. The reasons for the defects are analyzed, and the pouring process plan is optimized to eliminate defects in the limit hook position of the casting.