Simulation pretreatment of casting process for steel castings of railway couplers

The coupler body and casting process are modeled by proe and exported by Parasolid interface file format XT mesh file, import it into meshcast for finite element mesh generation, and get Mesh mesh file, with 95337 final face nodes and 443080 face elements. The finite element mesh model is shown in the figure.

Thermophysical parameters directly determine the accuracy of numerical simulation of railway coupler casting process. The value of thermophysical parameters is mostly a function of temperature, that is, temperature related parameters. In the numerical simulation equation, each time step may contain multiple physical values. If the value of thermophysical parameters is inaccurate, it is difficult to ensure the accuracy of simulation results.

The steel casting of railway coupler is made of ZG25MnCrNiMo, which is a high-strength low-alloy Grade E steel. There is no fully corresponding brand in ProCAST material library. The thermophysical parameters can be calculated by using the thermodynamic database of ProCAST’s own basic alloy system to obtain the thermophysical parameters such as liquid / solid limit temperature, solidification latent heat, specific heat, solid rate, thermal conductivity and density; At the same time, in order to conduct more accurate stress simulation, according to the element composition of ZG25MnCrNiMo and relevant data, the temperature related parameters such as young’s modulus, Poisson’s ratio, coefficient of thermal expansion, yield strength and shaping modulus are set. The molding material is wet molding clay sand. In order to simplify the calculation, triethylamine resin sand core is not involved in the simulation. Some thermophysical parameters set include (temperature related parameters are not listed): liquidus temperature 1505 ℃, solidus temperature 1433 ℃, solidification latent heat 65kj / kg, Poisson’s ratio 0.3, molding modulus 2102psi, pouring temperature 1585 ℃, ambient temperature 25 ℃, heat transfer coefficient between steel castings of railway couplers and wet clay sand mold 500 W / (M2 · K), pouring time 25s, and the operating parameters adopt the default value.

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