蜗轮箱座铸钢件的铸造工艺设计及数值模拟
Design and Numerical Simulation of Casting Process for Steel Casting Worm-gear Boxseat
陈立林，米国发，王有超
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作者单位：（河南理工大学 材料科学与工程学院，河南 焦作 454000）
中文关键字：蜗轮箱座；数值模拟；凝固过程；工艺优化
英文关键字：worm-gear boxseat; numerical simulation; solidification process; process optimization
中文摘要：运用传统方法完成了对铸钢件JH-14回柱绞车蜗轮箱座的铸造工艺设计。根据蜗轮箱座较为复杂的结构特点，同时设计两个内浇道对铸件进行浇注，在铸件顶部设计两个明冒口，在其侧面设计冷铁，以确保铸件的顺序凝固。建立铸件的三维实体模型，运用View Cast铸造模拟软件对铸钢件蜗轮箱座的凝固过程进行了模拟计算。模拟结果表明，在铸件的厚大处和壁与壁的交接处产生了缩孔、缩松缺陷。根据数值模拟结果并结合理论分析，通过加大冒口颈与冷铁的尺寸和增设冒口方法，对铸造工艺进行优化。最终模拟结果显示，优化工艺能将缺陷转移到冒口中，实现了顺序凝固，从而最大程度地消除了铸造缺陷，获得了合理的铸造工艺方案。
英文摘要： The casting process of steel casting JH-14 worm-gear boxseat was designed by using traditional methods. According to the complex structural characteristics of the worm-gear boxseat, the two side pouring sprues were adopted, and the two open risers along with chills were designed on the top of the casting to ensure progressive solidification. The 3-D model of the casting was built and the Viewcast casting simulation software was employed to simulate the solidification process of the steel casting. The simulation shows that the shrinkage defects forms at the thick shell and the joint of the shell. According to the results and combining with theoretical analysis, the casting process was improved by increasing the size of riser neck and chills and adding the number of the riser. The results show that the shrinkage only appears at the riser because the progressive solidification is achieved, the shrinkages in the casting are avoided. Then the reasonable casting process is obtained.