基于数值模拟的捣固装置用箱体及镐臂铸造工艺优化

Optimization of the foundry techniques for the housing of tamping unit and tampingarm based on numerical simulation

铸件经常出现难以预测的铸造缺陷,以气孔、夹渣、关键部位缩孔、缩松最难以判断。使用华铸CAE铸造工艺分析模拟软件,通过直观地分析充型、凝固过程,能够很大程度预测铸件可能出现的缺陷位置、缺陷大小、缺陷类型等。文章通过华铸CAE数值模拟结合实际生产情况,分析捣固车型箱体、镐臂缺陷产生位置及原因,然后优化补缩、浇注系统,增加集渣排气措施等,提高铸件的补缩、排渣效果,解决铸件的缩松缩孔、夹渣气孔及裂纹等缺陷问题,制定较为合理的铸造工艺,提高铸件的质量稳定性。

Unpredictable defects are often produced in castings,and it’s especially true with porosity,slag inclusion and shrinkage porosity in key area.With the help of Huazhu CAE analytical simulation software for casting process,the position of possible defects in a casting,defect size,defect type could be predicted to a great extent through intuitive analysis of the filling and solidification process.By means of Huazhu CAE numerical simulation,together with practical production,this paper analyzes the locations and causes of the defects in the tamping car and tamping arm,and then suggest to optimize feeding and gating system,implement additional slag collection and slag discharge measures to strengthen their effects on castings,so as to get over the defects,such as shrinkage,porosity,slag inclusion,slag inclusion pores,etc.,formulate more rational casting processes,and therefore improve the stability of casting quality.The paper also puts forward effective solutions to slag inclusion pores on the surfaces of complicated casting housings,feeding methods for complex structures in order to better guarantee the quality stability of complex castings.