Generally, for the newly put into production lost foam Castings, engineers and technicians rely on experience to select pattern density, pouring temperature, negative pressure, coating and other parameters, and design the pouring system through repeated experiments and modifications, so as to finally complete a more reasonable casting process. However, the trial production often takes a long time, usually several months or even longer. There is a great risk that the casting technology used by casting enterprises will disappear, but there will be a lot of risks.
Hefei Casting and forging factory uses lost foam casting technology to produce gray cast iron gearbox box castings. The traditional “experiment + experience” method is used to design the casting process. Even if there is a lot of investment, there are still many shrinkage porosity and shrinkage cavity defects in the gearbox box produced in the experiment, which makes the quality of the box can not meet the factory requirements. However, with the help of numerical simulation technology, we can analyze the causes of shrinkage porosity and shrinkage defects and guide the actual production. This is because with the help of numerical simulation technology, the distribution of temperature field in the flow and solidification of liquid metal during the mold filling process of gray cast iron gearbox box can be mastered. And the reasonable production process can be obtained through repeated computer simulation.
In view of this, mainly through the numerical simulation software, combined with the actual production process of box type lost foam casting, the lost foam casting process of gray cast iron gearbox box casting is numerically simulated, and the casting process is optimized according to the analysis of the simulation results, so as to reduce the shrinkage defects and improve the product quality. In order to determine the best casting process, comparative simulation can be used to study the filling and solidification process. Through the numerical simulation of the casting process, the causes of the defects in the casting process can be found out in time, and the waste mold can be found and improved in the casting process by using the software; Moreover, it has an important impact on the shortening of the trial production cycle of new products and the saving of human and material resources. It has a certain practical significance for the high-efficiency and high-quality production of box lost foam casting.