China has entered the ranks of the world’s largest foundry countries, and the production scale and types of castings of the foundry industry have entered the forefront of the world. However, China’s foundry industry still has a high scrap rate. The scrap rate of ordinary iron castings in China is about 10%, that of complex and high-grade parts is about 10% to 15%, and that of aluminum alloy die castings is about 8% to 10%. The defects of castings are mainly shrinkage cavity, porosity, air hole, sand hole, etc., of which about 80% of the defects can be eliminated by repair. There are many reasons for casting defects, such as casting process arrangement, material selection, casting mold design and manufacture, pouring molding and other links. If they are not designed and implemented in strict accordance with the standards, they will lead to the emergence of waste products.
With the development of the world economy, if China wants to be recognized in the global casting field, it will put forward higher requirements for casting technology and technology. If casting production wants to move towards the sustainable development path of high quality and low consumption, the casting technology and level must be improved as a whole. However, subject to the actual situation of the casting industry, the casting technology and level cannot be greatly improved in the short term. The development and research of casting CAE technology makes the application of casting forming numerical simulation technology in actual production become a reality. Using CAE technology, the mathematical model, materials and casting thermophysical parameters of castings and molds are input into the computer. The changes of temperature and speed, solidification defects and microstructure in the process of casting forming can be clearly displayed through images. By analyzing the causes of defects, and then modifying the process scheme, So as to reduce defects.
Based on the casting simulation technology, the casting simulation software ProCAST is proposed to simulate and analyze the casting filling and solidification process of typical reducer box, simulate different process schemes, and simulate from the aspects of pouring temperature, pouring speed, pouring system and casting structure, so as to find the optimal process parameters, so as to reduce casting defects, improve casting quality and save production cost, Shorten the production cycle of castings. Based on the discrete element visual simulation technology J, the coupling method of edem and fluent is used to study the influence of multi-dimensional vibration on the mold filling ability of castings under the condition of solid-liquid two-phase flow, explore the sensitivity of casting mold filling process to different vibration conditions, try to obtain the multi-dimensional vibration conditions suitable for the casting forming process, and provide a basis for semi-solid casting simulation and the design of vibration casting equipment in the future.