With the help of the designed test and simulation, the database of thermophysical parameters of sodium silicate sand mold and casting mold boundary conditions is established to solve the lack of boundary condition database in the simulation of casting process. Through the simulation of flow field and temperature field in the casting process, the gating system of typical castings is optimized, so as to lay a foundation for the production of high-quality large castings.
With the rapid development of China’s energy, metallurgy and other industries, the trend of large-scale equipment urgently needs high-quality steel ingots for supporting large castings and forgings. At present, the manufacturing level of large castings in China is not high, and many large key and high-end castings rely on imports. Large castings have the characteristics of single piece and small batch production. It is not allowed to produce through repeated tests and continuous adjustment of the process. With the help of computer simulation of the casting process, it can provide a basis for formulating the best process scheme, ensuring the quality of large castings, shorten the trial production cycle and reduce the production cost.
The lack of boundary condition database has become one of the main bottlenecks of casting process simulation technology. Therefore, the state attaches great importance to it and has invested a lot of human and financial resources. It is proposed to obtain the thermophysical parameters of sodium silicate sand mold through the inverse algorithm, obtain the heat transfer coefficient of the casting mold interface by using the inverse module of the software, analyze the heat transfer mechanism of the interface, study the flow field and temperature field in the casting process of large hydraulic turbine blade through finite element simulation, optimize the gating system, and analyze the possible casting defects such as shrinkage cavity and porosity, so as to guide the actual production.