Numerical Simulation of Casting Filling Process
The casting filling process is one of the most important processes in the production of cast parts. This process determines the quality of the parts and the production efficiency. Through the numerical simulation of the filling process, the internal characteristics of the process can be understood and the continuous improvement and optimization of the casting process can be realized.
Numerical simulation of castings filling process includes two parts: fluid dynamic analysis and filling solidification process simulation. The fluid dynamics analysis is the fundamental of the process simulation. For castings filling process, the filling pressure, flow field, mold temperature, filling speed and other parameters of the casting system need to be obtained by adopting CFD techniques. The calculation results such as fluid flow velocity, flow path and local pressure are obtained by solving the momentum, energy and continuity equations of the fluid dynamic system. The analysis result can support the reasonable process parameters.
In addition, the whole process of casting filling needs to be simulated by finite element method, which can realize the process tracing of filling, cooling and solidification in the casting process. According to the actual process parameters obtained by fluid dynamics analysis, the software of casting filling simulation can be used to accurately simulate and analyze the influence of filling speed, mold surface temperature and other control parameters on the process, and obtains the filling and cooling process of castings. The result can help to optimize and improve the process parameters.
Similar to the filling process, the results of the simulation of the solidification process of the casting can be used to effectively analyze the potential problems during the casting process, such as surface shrinkage, cracking and shrinkage cavity, etc. By combining process simulation with numerical simulation, a series of key problems such as casting defects, thermal stress and deformation can be thoroughly studied, and the optimized process parameters can be obtained by iteration simulation.
In summary, numerical simulation of casting filling process is based on fluid dynamics and finite element temperature field, which can realize the analysis of casting filling process and optimize the casting process parameters. The results of the analysis and simulation can effectively avoid potential problems in the casting process and improve the production efficiency and product quality of cast parts.
