In order to further verify the simulation results after the process optimization of steering knuckle steel castings and analyze whether there is any auxiliary guidance in actual production, in ProCAST, the relevant parameters before and after the process optimization were set to be consistent. According to the process optimization measures for steering knuckle steel castings, 216 steel castings were produced, of which 3 steering knuckle steel castings had sand holes and other defects, and the comprehensive quality qualification rate of steel castings reached above 98.6%. Trial machining and anatomical verification were conducted on the thick parts of the optimized steering knuckle steel casting (as shown in the figure). The transverse and longitudinal machining and anatomical results showed that there were no casting defects. The results showed that:. Selecting a reasonable casting process through casting CAE simulation technology can significantly improve the quality of castings.
(1) Using casting CAE simulation technology to assist in process design, the location of casting defects in steering knuckle steel castings was accurately predicted, and the simulation results were basically consistent with the actual defect distribution.
(2) Casting CAE simulation technology can significantly shorten the process validation cycle for engineering technicians to trial-produce new products and tackle product quality issues, reducing unnecessary repetitive work.
(3) The adoption of optimization measures significantly improved the product quality qualification rate of steering knuckle steel castings, and the unqualified rate of steel castings decreased from 21% before the optimization process to 1.4%, increasing product economic benefits.