Solidification numerical simulation and process optimization of Dia120mm wear resistant casting ball (3)

2.2 Analysis of process optimization parameters

The die core parameters and a sprue of the optimized process are shown in figures 8 and 9. The variation of the parameters of the ball casting’s specific position and the yield rate of the ball casting before and after the scheme is shown in Table 1.

It can be seen from Table 1 that the yield of the ball casting process is increased by about 2.8% after optimization.

2.3 simulation analysis after process optimization

The solidification trend of the optimized process is basically the same as that of the original one. When the casting is finished, the temperature field inside the casting is almost evenly distributed. With the increase of the solidification time, the temperature field layers are obvious, and different isothermal zones appear; in turn, the temperature increases gradually from the outside to the inside, and the highest temperature is in the center of the runner. The last shrinkage hole still appears inside the runner.

previous and advanced mold core
stright pouring gate

Although the optimized process’s solidification trend is basically the same as that of the original process, there are some differences in their temperature field. In order to compare the difference, the temperature field of the original process and the optimized process (as shown in Fig. 10) is taken for 900s.

900s temperature place

As can be seen from Fig. 10, during solidification to 900s, the distribution of the high-temperature zone in the optimized process is wider than that in the original process. This is because the die core in the optimized process is smaller than the die core in the original process, which indirectly causes the sand sleeve in the optimized process to be thicker than the sand sleeve in the original process, so the heat preservation effect is more obvious, the solidification of the optimized process is slower than that of the original process.

3.Conclusion

As can be seen from Fig. 10, during solidification to 900s, the distribution of high temperature zone in the optimized process is wider than that in the original process. This is because the die core in the optimized process is smaller than the die core in the original process, which indirectly causes the sand sleeve in the optimized process to be thicker than the sand sleeve in the original process, so the heat preservation effect is more obvious, the solidification of the optimized process is slower than that of the original process.

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