On the basis of consulting a large number of references at home and abroad, the relevant theories and methods of numerical simulation technology of sand casting process are elaborated in detail. Taking the flywheel casting process gating system as the research object, the numerical simulation analysis of mold filling and solidification process is carried out, and the application of numerical simulation technology in actual production is demonstrated: the stress field analysis of sand casting solidification process is a very complex problem, The numerical simulation of the stress field of the stress frame of the typical specimen was successfully realized by using the thermal analysis module of the large-scale finite element analysis software ANSYS 10.0, and the results were compared with the simulation results of the stress frame of the typical sand casting using ProCAST software: the connection between ProCAST and ANSYS 10.0 was studied. Main conclusions are as follows:
(1) Through the review of the application of temperature field, solidification process value simulation and stress field numerical simulation in sand casting at home and abroad, it is shown that the numerical simulation technology of sand casting system is vigorously promoting the development of casting industry, which plays an important role in optimizing sand casting process design, analyzing shrinkage, porosity and segregation, preventing hot crack defects, reducing residual stress, and improving the quality of sand casting.
(2) Study the pre-processing method of ProCAST, solve the problem of data transfer from the geometric model of sand casting established by Pro/ENGINEER to ProCAST software, and compare with other pre-processing methods. The results show that using Pro/ENGINEER modeling, mechanica module to divide the surface mesh, reading through MeshCAST, and then dividing the volume mesh is the most efficient pre-processing work route of mesh division.
(3) The ProCAST sand casting simulation software is used as a numerical simulation tool to simulate the filling and solidification process of the flywheel sand casting process produced by the current enterprise, optimize and improve its gating system, and verify that the improvement scheme is reasonable through production, providing a new technical approach to solve the problems in the sand casting production process.
(5) ProCAST software has been able to better reflect the metal flow process during sand casting in terms of flow field prediction. It can accurately predict the plain flow and air entrainment in the sand casting process, and the application of ProCAST software can more accurately predict the shrinkage cavity, shrinkage porosity, hot crack and other sand casting defects that may be formed in the sand casting process.
(4) According to the thermal and stress characteristics of sand mold casting process, the thermal elastoplastic model equation of sand mold casting during the solidification process and after the solidification stage is established, and the casting/mold boundary conditions and the values of material high temperature mechanical properties parameters are comprehensively analyzed. The numerical simulation of the three-dimensional temperature field and thermal stress field of the typical sand mold casting – stress frame is conducted without the finite element analysis software ANSYS, and the stress field simulation results are consistent with the reference documents, Through the comparison between the simulated stress results of typical sand castings with ANSYS and the simulated stress results with ProCAST software, I found the combination of the two software and established the flow analysis of the two software interfaces.