AnyCasting software was used to simulate the mold filling and solidification process ofpunch disc . The simulation results showed that after the molten iron entered the mold cavity, the mold filling was stable without obvious splash; When the mold filling is 40%, the average speed of molten iron in the casting is 51 cm / s, which tends to be stable without sand flushing risk; At the end of mold filling, the risk of oxidation inclusions is reduced; The temperature of molten iron decreases by 50 ℃, the temperature difference is small, and there is no cold shut risk.
1. Mold filling sequence simulation
Figure 1 shows the simulation results of the filling sequence. From the figure, it can be seen that when the molten metal is filled for 12 s, there is an isolated liquid phase island at the inlet of the ingate, with a splash tendency. The time difference between here and the end of the ingate is 24 s, which is relatively safe. When the mold is filled for 43 s, the time for the molten iron to reach each position of the mold cavity is relatively uniform, and the mold filling is stable.
2. Mold filling velocity field
Figure 2 shows the simulation results of the mold filling velocity field. From the figure, it can be seen that when the mold filling is 14%, the velocity at the inlet of the inner runner is 160 cm/s, and the velocity is moderate. When the mold filling is 40%, the average velocity in the disc of the ductile iron punch is 51 cm / s, and the velocity tends to be stable, without sand flushing risk.
3. Oxide simulation
Figure 3 shows the simulation results of oxides during the filling process. It can be seen from the figure that when the filling is 17%, the oxide content of the bearing seat hole process table is 4.2 g/cm3, which has the risk of oxidation inclusions. At the end of the filling, the oxide content on the upper surface of the casting is 3.58 g/cm3, which reduces the risk of oxidation inclusions.
4. Mold filling temperature field
Figure 4 shows the simulation results of the filling temperature field. It can be seen from the figure that the temperature of molten iron decreases by 30 ℃ when the filling reaches 26%, and the temperature of molten iron decreases by 50 ℃ when the filling ends. The temperature difference is small, and there is no cold shut risk.