In recent decades, with the continuous development and progress of computer CAD / CAM / CAE technology, lost foam casting simulation technology is becoming more and more mature. This simulation technology not only reduces the production cost, but also improves the competitiveness of lost foam casting enterprises, which plays a very important role. In the traditional lost foam casting production process, engineers mostly use trial and error method for production, which is lack of scientific theoretical basis for guidance. For castings with complex shape and high quality requirements, lost foam casting samples are usually made for testing. After repeated modification, reasonable process products are finally obtained. The manufacturing cycle is long, which brings huge economic losses to the enterprise, affects the casting quality and production cost, seriously restricts the development of the enterprise and affects the technical progress of lost foam casting enterprises.
The ball mill liner is used to protect the cylinder from the impact and friction of the grinding body and materials in direct contact. Therefore, it must be able to withstand wear, impact, corrosion, etc. In China, the lining plate of high manganese steel ball mill is gradually replaced by alloyed high manganese steel lining plate. When the liner of ball mill is cast in sand mold, it is easy to produce sand sticking, large casting stress and easy to cause crack and deformation. Many scholars at home and abroad have done a lot of research in numerical simulation. Zhang Bo simulated and analyzed the temperature field in the casting process to predict the possible location of shrinkage porosity and shrinkage cavity; Chen Ling et al. Used ANSYS simulation software to predict the location of shrinkage porosity and shrinkage cavity in iron castings; Zhou Jian et al. Simulated the temperature field and flow field in lost foam casting process by software simulation and SOLA-VOF algorithm, and obtained a conclusion consistent with the experimental results. In terms of mold filling and solidification process of lost foam casting, computer numerical simulation technology provides people with an intuitive understanding of predicting shrinkage cavity and porosity. Numerical simulation is of great significance to reduce test cost, optimize lost foam casting process, shorten production cycle, improve casting quality and improve yield.
(1) The influence of riser position in lost foam casting on the degree of shrinkage porosity is different. In order to eliminate the defects of shrinkage porosity and shrinkage cavity, the position of riser needs to be changed to achieve the effect of feeding.
(2) Through the comparison of two sand mold numerical simulation process schemes of silicon sand and iron sand, it is found that the mold filling, exhaust and scum effects in the process of iron sand pouring are good, which saves a lot of time and improves the performance and quality of lost foam castings.
(3) The casting simulation of high manganese steel lining plate in lost foam casting was carried out by using ProCAST casting simulation software, and the simulation results of mold filling and solidification process were analyzed.
Taking the lost foam casting process of ball mill liner as an example, the process is numerically simulated by ProCAST software to predict the location of defects. By improving the process scheme, the mold filling and solidification process were simulated, and the solid phase distribution and solidification time distribution were analyzed.