Through the research, a complete process route of rapid sand mold casting is obtained.
① ugnx8 0 software to establish the cylinder head model;
② Using the rapid sand mold casting process CAD system based on light curing prototype developed by the laboratory to design the casting process of the cylinder head, including the setting of parting surface, material setting, modification of process parameters, design of gating system, riser design and sand core design;
③ The casting process of ProCAST is analyzed;
④ Select modeling materials, make prototype models and cast products.
According to the above process, the interface heat transfer coefficient is solved by using ProCAST’s inverse heat conduction model. Then the designed casting and mold are meshed by visual mesh. Using the parameters and actual boundary conditions obtained from the previous reverse solution, and taking the casting simulation software ProCAST as the simulation tool, the filling and solidification processes of three pouring methods for the production of ZL105 aluminum alloy cylinder head are simulated. The simulation results of three cases are compared and analyzed. The problems such as whether the metal liquid can fill the mold smoothly, whether the phenomena of “rolling up” and “sand flushing” occur, whether the metal liquid can fill the mold cavity smoothly, whether the solidification meets the sequential solidification conditions after the metal liquid fills the mold cavity, and whether the riser can fully feed the casting during the solidification process are discussed.