According to the actual production situation of sand casting, on the basis of summarizing and analyzing the theory of sand casting simulation, the numerical simulation software procast2008 is used to firstly simulate the filling and solidification process of the flywheel casting process currently produced by the enterprise. According to the simulation results, the optimization design and improvement of the casting system of the flywheel are carried out. The stress field simulation of sand mold casting process was studied by means of large-scale finite element analysis software ANSYS10.0. Through the analysis and comparison of the stress simulation results of sand casting by ANSYS and ProCAST, the relationship between the two is found out, which provides an idea for solving the interface connection between the two software, mainly including the following research contents:
(1) The development status of numerical simulation technology of sand casting process in China and various numerical simulation software are analyzed and summarized, and the development prospect of numerical simulation technology of sand casting process in the future is put forward.
(2) The tasks and contents of numerical simulation are summarized. The theoretical basis of numerical simulation of mold filling, solidification and stress field is studied and analyzed from the mathematical model, numerical algorithm and defect basis.
(3) Pro / Engineer 3.0 was used as solid modeling software, and sand casting technology was added; Then the mesh division and parameter setting are carried out; The interface between CAE software Pro / Engineer 3.0 and numerical simulation software procast2008 is studied.
(5) According to the actual situation of the trial production site, the database of thermal physical parameters, heat transfer coefficient and initial conditions of sand casting materials suitable for enterprise application is established, the initial conditions and boundary conditions are loaded, and the simulation analysis of the mold filling and solidification process of Flywheel Casting is carried out by using procast2008 software. According to the analysis results, the sand casting process scheme of flywheel is improved.
(6) Considering the characteristics of material properties changing with temperature, the numerical simulation of typical casting stress frame sand mold casting process was successfully simulated with the help of ANSYS10.0 by using nonlinear analysis. The numerical simulation results of temperature field and stress field were compared with those of procast2008.
(7) The flow analysis of the connection between ProCAST and ANSYS is made, which lays a foundation for the connection between them.