压壳铸件的铸造工艺设计及试生产

Casting Process Design and Trial Production of a Shell Body Casting

压壳铸件应用于许多流体工程领域中。根据压壳铸件的结构特点,首先基于其CAD图利用UG软件对该铸件进行了三维建模,然后设计其铸造工艺方案,并利用数值模拟软件ProCAST进行了工艺方案优化,分析了铸件的充型过程、凝固过程及缩孔、缩松缺陷分布等,最终确定了压壳铸件的最佳铸造工艺方案。再采用树脂砂利用数字化无模精密铸造成形机加工出砂型及砂芯,然后合型,熔炼金属液,进行实际浇注,对压壳铸件进行了试生产。所获得的铸件完全符合图纸的技术要求,为该压壳铸件采用重力铸造方法进行下一步中试生产奠定了工艺基础,同时也为其他压壳类铸件的铸造工艺设计提供了一定参考。

Shell body castings are widely used in the field of fluid engineering. In this paper, according to the structural characteristics of a shell body casting, the 3D model of the casting was first established with the UG software in accordance with its CAD drawing, then its casting process scheme was designed and optimized with the ProCAST numerical simulation software. After analyzing the filling process, solidification process and defect distribution of shrinkage cavities and porosities, the optimal casting process scheme was finally determined for the shell body casting. Next, with the resin bonded sand, the desired sand molds and sand cores were prepared by use of the digital patternless precision casting molding machine. After assembling the molds &cores, melting and pouring the ZL101A alloy, the trial production of the shell body casting was completed.The obtained casting fully met the technical requirements of the CAD drawing, which lays a technological foundation for the next step of pilot production of the shell body casting by the gravity casting method, and also provides a certain reference for the casting process design of other pressure shell body castings.