The design of sand casting process plays a key role in the quality of castings. The traditional process design of sand casting mostly depends on experience, so for the process of complex sand casting, it can not be designed successfully at one time and needs continuous test, which not only increases the cost of sand casting, but also wastes time. With the development of computer technology, computer simulation of mold filling and solidification process of sand casting has been widely used, which plays an important role in the rational design of sand casting process.
AnyCasting software is used to simulate and analyze the sand casting of the excavator rear axle housing produced by a factory according to the original process, and the casting defects are predicted. The results are consistent with the actual production. Aiming at the defects of sand casting, the gating system and riser type of sand casting are improved, which greatly reduces the probability of sand casting defects, and improves the process yield of sand casting, which provides a basis for guiding the actual production.
The rear axle housing of wheel excavator is an important security part of excavator. It bears heavy load and changing bending moment during the driving of excavator, and is prone to bending fatigue fracture. Therefore, the rear axle housing should have good rigidity and fatigue strength performance. The interior and surface of sand casting are not allowed to have cold lap, crack, shrinkage cavity, permeability defects and serious incomplete casting defects. The sand casting of rear axle housing has special structure and large wall thickness difference. In the past sand casting production, the probability of various defects is large and the process yield is low. As shown in the figure, it is a solid drawing of sand casting of excavator rear axle housing, with a size of 1548 mm × 431 mm × 362 mm, mass 215 kg, material zg270-500.
AnyCasting software is used to simulate the original sand casting process of the rear axle housing casting, predict the defect distribution position, and optimize the process according to the simulation results, including the design of gating system, riser and cold iron, the adjustment of fillet, pouring time and the technical improvement of coating. The optimized process simulation results show that the casting defects are basically solved. It can be used as a reference for the process design of similar sand castings. Using computer simulation technology to assist process design can not only save process trial production time, improve work efficiency, but also reduce cost and greatly improve process yield.