Discussion on tooling design of sand casting coupling parts

When CAD and CAE technology are used to assist the design of gating and riser system of sand casting coupling parts, the design steps are different from the previous design ideas; The previous design steps are usually to formulate multiple sets of pouring and riser system tooling of sand casting coupling parts at the same time according to theory and experience, and make the solid modeling of these tooling respectively. Then CAE simulation is done for each set of pouring tooling to obtain the analysis results. Finally, the simulation results of different tooling are comprehensively analyzed, the advantages and disadvantages are compared, and the best design scheme of gating and riser system of sand casting coupling parts is selected to determine the process. The defect of this design idea is obvious;

1.The sand casting defects of a single coupling part are often caused by many different reasons, and if the simulation results of each set of gating and riser system tooling of sand casting coupling parts with high completion still find defects, it is difficult to directly determine which reason has a greater impact on the defects, Sometimes the specific causes of defects can not be determined, which is not conducive to the optimization of pouring process and the determination of optimal pouring and riser system.

2.At the same time, formulate multiple sets of tooling, solid modeling of multiple sets of tooling and CAE simulation for each set of gating and riser tooling. When the part structure of sand casting coupling and gating and riser system are relatively complex, it will greatly waste the human investment of the enterprise and prolong the R & D cycle of new products.

Firstly, two sets of gating and riser systems of sand casting coupling parts with low completion are determined, and then CAE simulation is carried out. According to the simulation results, the gating and riser system is further completed and optimized. This is repeated until satisfactory simulation results are obtained to determine the gating and riser system. This step-by-step improvement of the pouring and riser system is more conducive to determine the causes of defects, but also reduces unnecessary human investment for enterprises. However, to do so, a single casting engineer is required not only to have the theoretical knowledge and certain casting experience of casting process design and analysis, but also to have the ability of CAD solid modeling, CAE simulation and result analysis. It has higher comprehensive ability requirements for a single casting engineer. Using the previous CAD and CAE aided design method of pouring and riser system, the whole design process is often completed by division of labor, and even can be completed jointly by casting enterprises and mold enterprises.

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