CAE analysis technology is casting the application in production

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Summary: In recent years, software of simulation of computer foundry technology begins institute of the plant that be cast by great majority to accept, it is OK to use these softwares relatively accurate forecast all sorts of casting blemish, optimize gating system design, eliminate the crackle flaw such as hot tearing, raise craft to manufacture rate. The article introduced to apply ProCAST software to optimize a few example in the design in practical foundry technology, apply those who show this software can be accurate to forecast cast a variety of casting blemish, be helpful for foundry technology optimize the quality with cast to rise. Keyword: ProCAST CAE numeric imitate casts 1 foreword to cast one of principal property parts that are national economy, it mirrorred a country to make industrial dimensions and standard. As the bitter fleabane of each industry such as aviation, spaceflight, shipping, car, machinery suddenly develops, the demand of cast is bigger and bigger, taller and taller to casting the requirement such as the dependability of metallic function and cast itself. The development of advanced production technology, the production of requirement cast to light-duty change, change accurately, Jiang Ren is changed, compound change reach without the environment contaminative way develops. The flying development of computer technology and its are casting the wide application in production, can pass pair of workmanship processes to undertake counting is worth imitate to reach emulation, make afore-mentioned targets are able to come true. This job is basic method with numeric computation, appearance of body of microcosmic to casting process midstream field, temperature field, stress field to reach organization undertakes imitate, help craft design personnel to shed temperature of voice, caky process to distributing to the metal of different hour thereby, stress distributings, the important physics parameter such as appearance of shape of crystallization grain size understands somewhat, it is a basis with this, forecast whether to have shrinkage cavity, loose, be mingled with, slant the blemish such as analyse and hot crack appears, can realize mold design -- school nucleus -- design again -- the whole process that optimizes a design, in order to improve cast quality, shorten trial-produce is periodic, reduce manufacturing cost, raise the market to dispute ability unexpectedly. In the meantime, using the new and high technology such as the computer to transform production convention industry is the collective tendency that domestic and international science and technology develops, it is the course forward position that casts a domain, also be foundry technology by " experience is designed " trend " science is directive " important way, have great real sense. Graph the 1 whole technological process that revealed cast craft to optimize. 2 ProCAST software introduces in recent years, cast function of CAE commercial software to increase gradually, the software such as the Soldia of the Forcast of the Simulor of the MAGMASOFT of the ProCAST that basically has the United States among them, Germany, Finnish CastCAE, France, Spain and Japan, Castem. Look from the function, a lot of software are based on finite calculus of finite differences mostly, can cast to sand mold, metal mold is cast, nicety is cast, a variety of craft such as die-casting have temperature field, shed the numeric imitate of field, the shrinkage cavity that can forecast cast, shrink the blemish such as the pine, but forecast to what the imitate of stress field reachs crackle appear ability not equal to one's ambition. ProCAST software is be based on by what ESI company develops finite yuan of law (FEM) cast process simulation software, can undertake drifting field, temperature field, stress field 3 coupling imitate. ProCAST is used be based on finite yuan of law (FEM) numeric calculation method, with finite calculus of finite differences (FDM) photograph comparing, finite yuan the law has bigger flexibility, special apply to imitate complex cast shapes all sorts of physics phenomena in the process. ProCAST was offerred can consider gas, filter, high pressure, rotate wait to be filled to cast model influence, can imitate gives low Die Casting to build, of the almost all foundry technology such as die-casting, centrifugal casting fill model process; The respect is analysed in stress, play through using plasticity and stick plasticity and particular processing cast / the method of casting mould heat and mechanical contact interface, make its have capacity of analytic cast stress, metabolic. Can obtain those who cast a process through the analysis all sorts of phenomena, cast blemish to form reach distributing, the imitate of final quality mixes cast forecast. Graph the 2 move that undertake for ProCAST software imitate is analysed. Nextpage3 application example 3.

1 cast is filled model imitate is cast fill model the action with decisive to the move since the final quality of cast process, a lot of casting blemish, if irrigate insufficient, cold lie between, roll slag inclusion of gas, oxidation and even shrink loose, shrinkage cavity fill with what cast model closely related the process, use ProCAST software can relatively accurate expression is filled model process and blemish build a course, this is filled to optimizing model systematic design, avoid to fill model unreasonable the it is important to cast blemish to have sense that arouse. To examine ProCAST software is shedding an accuracy that forecasts a respect, we chose the J of British Birmingham.

The aluminium that Campbell undertakes is filled model fiducial experiment, come the accuracy of software of test and verify. The X- ray of test result is filled model the result is like Zun Tu, right graph is the imitate circumstance of ProCAST software, can see from inside the graph, proCAST software can accurate imitate is whole of cast fill model process, very good dope a gas blemish of gating system. Graph 3 actual and pouring with result of ProCAST software imitate contrast is in the mold design of impeller cast, we use the forecasted impeller cast gating system unreasonable design with ProCAST very good software, put forward craft to improve, make this cast pouring and successful. The impeller in designing technology formerly individually inside runner discharge distributings very unreasonable, classics the cast after improving is filled model relatively even, discharge of the runner inside each distributings relatively even. Graph 4 gating system improve around to contrast 3.

Caky imitate casts 2 cast major flaw basically is to shrink in the process pine and shrinkage cavity blemish, and these blemish are in mostly cast is formed in caky process, consequently, compare the caky process of accurate emersion cast, loosen to shrinking and of shrinkage cavity blemish forecast appear very important, proCAST software can relatively accurate forecast cast shrink pine and shrinkage cavity blemish, software offers a variety of is based on not to stabilize heat to conduct calculative cast to shrink pine and shrinkage cavity blemish forecast a method, have commonly usedly: Software of law of criterion of gradient method of temperature gradient method, solid photograph rate, caky time gradient method, Niyama and its mutation, ProCAST takes oneself beforehand the criterion related density. The engineer can pass the integrated application of a variety of criterion, achieve forecast shrink the purpose of pine and shrinkage cavity blemish. We are in optimize some cast steel when, used a variety of criterion integratedly, pass imitate several times to analyse, the cast in solving production successfully finally shrinks pine and shrinkage cavity problem. The craft classics imitate of original cast is analysed, applied temperature gradient method and gradient method of solid photograph rate show flawless, and applied ProCAST software shows from the criterion of the belt two place have shrink pine and shrinkage cavity blemish, this and result of concrete cast flaw detection are consistent, through much suboptimization, solved a problem finally, produces cast interior is compact flawless. Nextpage3.

Because the reason of cast structure respect and craft are handled,imitate of field of 3 cast stress enters the arena in casting production undeserved and occurrence hot tearing, perhaps put in greater leftover stress or remains to be out of shape in certain place, this is in cast steel especially large cast steel in exist generally, these limitation affected the quality of cast and service life badly, and these two kinds of blemish are mixed directly the generation of the thermal stress in caky process and development are concerned, iron is not hot tearing blemish, general generation is in area of accurate solid photograph, and the follow-up as cast is cooling, crackle expands ceaselessly, often cause cast to discard as useless. The cast steel that we are 35CrMo character in some material of production when, crackle often appears near runner inside, and often expand arrive cast is in-house, what affected succeeding activity badly is normal begin, workshop technician ever increased allowance of stage of a protruding near runner inside, in order to reduce crackle to cast patulous, but did not solve a problem thoroughly, later, applied ProCAST software undertook imitate to cast stress field, according to imitate circumstance, put forward to improve measure, comb-out the crackle blemish in cast. Graph 9 improve around inside runner stress distributinging contrast 4 conclusion (1) , ProCAST software is flowing forecast a respect, already the process of going from place to place of the metal when can better report is cast, can accurate forecast the turbulence in casting a process is mixed a gas. (2) , applied ProCAST software can relatively accurate forecast the place in casting a process to form shrinkage cavity, shrink loose, hot tearing cast blemish. CNC Milling