To study the numerical simulation and application of sand casting forming process, the main innovation is to use classical numerical simulation theory as guidance and advanced analysis technology as means to solve the problems existing in the production process of sand casting in enterprises, to solve the problem of using special mold filling and solidification simulation for analysis, and then to call the results of ANSYS for comprehensive analysis, It provides a direction for the application of self-developed numerical simulation software in engineering. The innovation points of the project are as follows:
(1) The problem of data transfer from the geometric model of castings built by PRO/ENGINEER to the numerical simulation software ProCAST is solved.
(2) Aiming at the casting defects of the flywheel currently produced by the enterprise, using the casting simulation software ProCAST as a tool, the mold filling and solidification process of sand mold casting was simulated, which accurately reflected the actual situation of the mold filling and solidification process of the casting, and predicted the possible casting defects and the location of the defects. The research results showed that the cold iron was placed near the hot spot of the casting, and the riser was placed at the final solidification position to make it solidified in order, It can effectively improve the hot spot state, and can achieve the purpose of eliminating and controlling defects. Moreover, the simulated flywheel casting can meet the quality requirements after actual inspection, which proves that the casting process optimized by numerical simulation technology is effective and feasible.
(3) Based on the thermo-elastic-plastic model and the effect of thermal-stress coupling technology and the transformation expansion and sand mold obstruction on the stress of the casting, the stress field of the casting after solidification was simulated by using the large general finite element software ANSYS, and the interface flow between the finite element software ANSYS and ProCAST was established.