It mainly simulates and optimizes the process of two parts: 17 coupler body and 16 coupler tongue, which are important connecting components of railway freight cars. The development trend of high-speed and heavy load of railway freight cars and the harsh service environment of connecting elements determine the necessity of high-quality steel castings, so as to reduce and avoid the occurrence of casting defects and parts failure as much as possible.
The failure forms of railway steel castings such as coupler body and coupler tongue are mainly fatigue fracture, wear and deformation. The main influencing factor of failure is the casting defects such as slag inclusion, sand sticking, shrinkage porosity and shrinkage cavity and micro cracks in steel castings to varying degrees. These defects form macro cracks under the action of alternating stress, resulting in direct fracture or fine debris, and accelerate the wear of coupler connection parts. Therefore, it is of great significance to simulate the mold filling and solidification process of steel castings, predict casting defects, optimize casting process parameters, ensure the quality of steel castings and reduce production costs.
For the process simulation and optimization of railway steel castings, firstly, UG and proe software are used to carry out the three-dimensional modeling and pretreatment of the original production process of the parts, and then ProCAST simulation software is used as the simulation platform to simulate and calculate the velocity field, temperature field and stress field during the mold filling and solidification process of the parts, so as to predict the possible casting defects such as sand flushing, slag inclusion and sand sticking, shrinkage porosity, hot crack, etc. on this basis, the process is improved and the casting process parameters are optimized, The improved and optimized process scheme is obtained. The numerical simulation results of the improved and optimized process scheme are greatly improved compared with the original scheme and meet the production requirements. After the actual production and trial production, the trial parts are basically consistent with the simulation results of the optimized process, and the quality is excellent, which provides an important reference for the determination of the batch production process of railway steel castings.