Realization of casting process simulation of trial production process

To realize the simulation of casting filling and solidification process by ProCAST, the following processes need to be experienced:

Firstly, carry out the three-dimensional modeling of the casting according to the two-dimensional drawing of the product, and then carry out the three-dimensional modeling of the gating system, riser, sandbox, etc. according to the characteristics and process scheme of the product, and assemble all parts together to export the document in the format suitable for the ProCAST grid processor. This step is the geometric modeling process; Then, the geometric model is divided and optimized by surface mesh and volume mesh in the mesh processor to obtain the volume mesh model that can be used for calculation, that is, mesh modeling;

Then, the grid model is imported into the preprocessor of the software, and the thermophysical parameters such as material parameters, initial conditions, boundary conditions and operating parameters are defined. The parameter control documents and model data documents that can be calculated are obtained, and the thermophysical model is established;

Finally, ProCAST converts and calculates the data of the obtained thermophysical model, and obtains the visual and controllable simulation results in the post processor. According to the simulation results, the foundry workers analyze the whole casting filling and solidification process in combination with the reality and basic theory, and finally obtain the ideal process scheme, and the whole process can be completely realized.

Therefore, the essence of simulation is to restore the actual pouring state by using the thermophysical model based on mathematical model, geometric model, material parameters and thermophysical conditions. Through the simulation of the trial production results of the above two trial production processes, a more accurate thermophysical model suitable for the site and material can be obtained.