Filling process and simulation analysis of molten metal in sand casting axle housing

In the filling process, the flow of molten metal will have a great impact on the quality of the axle housing, mainly by observing the fluidity of molten iron in the mold cavity, whether the molten iron flow rate is uniform, whether there will be turbulence, whether there is a situation of incomplete mold filling. If the design of the gating system is unreasonable, the axle housing will have casting defects such as cold shut, sand flushing, air entrainment, sand hole. Therefore, ProCAST was used to simulate the filling process of molten metal in axle housing to judge the rationality of gating system.

The higher the solidification coefficient of molten iron, the worse the metal fluidity. Through the comparison of the above images, the y-axis in the flow field represents the faster and faster flow rate. The red area represents the poor metal fluidity, and the green and yellow area represents the moderate filling speed. The solidification coefficient changes in the three filling schemes.

It is concluded that the closed gating system has a faster flow rate of molten metal and can be completely filled. The solidification coefficient of open gating system is too high at the later stage of flow, which results in poor metal fluidity, cold shut and insufficient pouring defects. The flow rate of the three semi closed gating system is relatively gentle.