For the sand casting flywheel, the casting simulation software ProCAST was used as a tool to simulate the sand casting filling and solidification process, predict the quality of the sand casting and the possible defects. Aiming at the defects, the 3D model of the gating and riser system was modified in Pro/ENGINEER software, and then the ProCAST software was used again to simulate until the simulation results met the process requirements.
The numerical simulation of the filling and solidification process of sand mold casting is analyzed with an example. The specific work is as follows:
(1) The advantages, functions and scope of use of Procast2008 software are briefly introduced, and the interface connection between ProCAST2008 software and 3D design software Pro/ENGINEER is studied. The research shows that the mechanical module of Pro/ENGINEER software can be used to mesh the 3D model first, and then the *. ans file is generated and imported into ProCAST2008 for volume mesh division, which can achieve the best connection between the two interfaces.
(2) Combined with practical work, 3D design and mesh division were carried out for the flywheel sand casting process gating system produced by the enterprise, and finally the numerical simulation analysis was carried out by using ProCAST2008. The macro shrinkage cavity in the sand casting was predicted by using the finite element software ProCAST, and the temperature field distribution, temperature gradient, liquid metal flow behavior, hot spot position, shrinkage porosity and shrinkage cavity during filling and solidification were visually displayed. According to the simulation results, The 3D model of sand casting process design was modified, and the original gating and riser design was modified according to the simulation results. The practice showed that the modified casting process was used to improve the quality of sand casting, improve the process yield, and reduce the cost.
Through the numerical simulation analysis of the flywheel pouring process plan, we can see the whole process of sand mold casting filling and solidification, and predict the location of sand mold casting defects. For different defects, we improve the process plan to eliminate or reduce the defects, so as to improve the internal quality of sand mold casting and achieve the purpose of optimizing the process. In order to improve the economic benefits of enterprises, the numerical simulation software of sand casting process will become a powerful auxiliary tool for foundry enterprises and foundry engineers.