基于ProCAST的悬梁铸造模拟及工艺优化

Casting Simulation and Process Optimization of Suspension Beams Based on ProCAST

利用ProCAST对机床悬梁的铸造工艺进行数值模拟分析,根据铸件充型和凝固的温度场、充型时间及缺陷分布,对初始铸造工艺进行优化。结果表明,铸件浇注时间为35 s,初始方案中,原因是由于壁厚较大而导致冷却缓慢,使得金属液向先凝固的地方进行了补缩,导轨部分出现了较大面积的缩松、缩孔缺陷。通过在铸件侧表面施加6个侧冒口和顶部施加4个顶缩颈冒口进行补缩,在导轨面添加17块冷铁以激冷的方式减少铸件缩孔缩松问题。仿真结果表明,优化工艺有效抑制了铸件缩孔缩松的形成,提高了铸件质量,对悬梁的生产起到指导性作用。

The casting process of the machine tool suspension beam was numerically simulated using ProCAST to optimize the initial casting process based on the temperature field,filling time and defect distribution of the casting filling and solidification.The results showed that the casting pouring time was 35 s,and the initial scheme showed a large area of shrinkage and shrinkage defects in the rail section,which was caused by slow cooling due to the large wall thickness,making the metal liquid to make up the shrinkage to the place where it solidified first.The shrinkage problem was reduced by applying 6 side riser on the side surface and 4 top shrinkage neck riser on the top of the casting and adding 17 pieces of chill to the rail surface to stimulate the cooling.The simulation results show that the optimized process effectively suppresses the formation of shrinkage holes and shrinkage loosening in the casting;improves the quality of the casting,and plays a guiding role in the production of the suspension beam.