Abstract
Pump body is the core flow component of the dredging pump, and its casting quality directly impacts the service life and overall efficiency of the dredging pump. This paper focuses on the numerical simulation and process optimization of sand casting for a dredging pump body. By utilizing advanced simulation software, the casting process was thoroughly analyzed to eliminate defects and enhance casting quality.
- Introduction
- Research Background and Significance
- Development of Casting CAE Technology
- Application of Casting Simulation
- Main Research Contents of This Paper
- Design of Gating System for Dredging Pump Body
- Design Principles of Gating System
- Classification of Gating Systems
- Design of Gating System for Dredging Pump Body
Table 1: Comparison of Gating System Designs
| Gating System | Characteristics | Advantages | Disadvantages |
|---|---|---|---|
| Bottom Gating | Simple structure | Steady filling | Large temperature drop, risk of oxidation and shrinkage defects |
| Step Gating | Complex structure | Better temperature gradient, smaller temperature drop | Potential for early in-gate filling, causing wall erosion |
- Filling Process Analysis of Dredging Pump Body
- Basic Equations for Filling Process Calculation
- Issues to be Solved in Filling Process Simulation
- Finite Element Mesh Generation
- Material Assignment
- Initial and Interface Conditions
- Simulation Results and Analysis
Table 2: Summary of Simulation Results
| Gating System | Filling Characteristics | Temperature Gradient | Metal Temperature Drop | Potential Defects |
|---|---|---|---|---|
| Bottom Gating | Slow and Steady | Poor | Large | Oxidation, Shrinkage |
| Step Gating | Faster, Sequential | Better | Smaller | Wall Erosion |
- Design of Feeding and Chilling Systems for Dredging Pump Body
- Design of Feeding System
- Design of Chilling System
- Optimized Process Scheme Based on Simulation Results
Table 3: Optimized Process Parameters
| Optimized Component | Changes Made | Purpose |
|---|---|---|
| Gating System | Redesigned | Better temperature gradient, controlled filling sequence |
| Feeding System | Adjusted | Enhanced feeding distance, reduced shrinkage defects |
| Chilling System | Added chills | Improved cooling efficiency, reduced hot spots |
- Solidification Process Analysis and Stress-Strain Analysis of Dredging Pump Body
- Theoretical Basis of Casting Simulation
- Simulation Results and Analysis of Solidification Process
- Prediction and Analysis of Shrinkage and Porosity
- Stress and Strain Analysis During Solidification
- Process Optimization of Dredging Pump Body Casting
- Optimization of Casting Process Scheme
- Simulation of Optimized Casting Process
Table 4: Comparison of Casting Defects Before and After Optimization
| Defect Type | Before Optimization | After Optimization |
|---|---|---|
| Shrinkage Defects | High Incidence | Significantly Reduced |
| Porosity | Present | Almost Eliminated |
| Oxidation | Present | Reduced |
| Wall Erosion | Moderate | Controlled |
- Conclusion
This paper presents a comprehensive study on the numerical simulation and process optimization of sand casting for a dredging pump body. By analyzing the casting process, designing and simulating different gating systems, and optimizing the feeding and chilling systems, significant improvements in casting quality were achieved. The optimized process parameters provided a better temperature gradient, reduced defects, and enhanced the overall performance of the dredging pump body. Future work will focus on further refining the casting process and exploring new materials and technologies to improve casting efficiency and quality.