ProCAST casting simulation process and purpose of sand casting axle housing

ProCAST casting computer simulation process: firstly, Creo software was used to establish the three-dimensional numerical model of the casting system of the axle housing, and saved in. STP format. Because of the complex structural characteristics of the axle housing, which belongs to the complex thin-walled axle housing, the visual mesh module under the ve environment of ESI is used to refine the local mesh of the axle housing. Check the geometry of the axle housing to see if there are redundant lines and surfaces. If there are errors, use the automatic repair function to repair the three-dimensional model of the axle housing. If it cannot be repaired, it needs to be modified in the 3D software. Then the assembly between the geometry is carried out. After assembly inspection, Boolean operation is carried out to generate internal sand core, cold iron, runner, etc. this function needs to check whether it is successful or not. If it fails, the model needs to be modified again. Finally, meshing was carried out to generate surface mesh and volume mesh, and the software check was correct. The quality of the body mesh after successful generation met the simulation requirements. Finally, all casting related parameters such as pouring direction, material setting, section parameter setting, pouring temperature and pouring time were set, and finally the casting simulation computer calculation was carried out.

The computer numerical simulation technology can be used to judge whether the casting process design is reasonable or not. By simulating the filling process of metal solution and the solidification process of liquid metal, the fluid situation in the pouring process and the possible casting defects in the cooling process of the axle housing can be analyzed.

In this design, Creo software is used to draw the three-dimensional drawings of different casting process systems, and ProCAST software is used The software carries out surface mesh division, surface mesh inspection, volume mesh division, volume grid inspection, etc., sets casting parameters such as pouring direction and interface value, selects gating system through numerical simulation analysis of liquid metal filling and solidification process of axle housing, designs riser feeding and chilled iron chill, so as to enhance feeding effect and realize optimization of casting process design.

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