Computer application in casting
The wide application of computers is driving the development and transformation of the foundry industry from all aspects. It can not only improve production efficiency and reduce production costs, but also promote the emergence of new technologies and new processes, so that casting production is moving from relying mainly on experience. Scientific theory guides the stage of production.
Simulation analysis and computer-aided engineering (CAE) applications can scientifically predict liquid metal filling processes, temperature and stress fields during solidification, and macroscopic defects and microstructure. It can optimize the commissioning process, ensure the quality of castings, shorten the trial production cycle, and improve competitiveness; it can achieve significant economic benefits while improving the production of castings. The application of computers in casting technology has played an unprecedented role in the following aspects.
1. Casting Process Computer Aided Design (CAD) technology mainly achieves the following functions, such as geometry and physical quantity calculation of castings (including calculation of casting volume, surface area, weight and thermal modulus); design calculation of casting system (including selection of casting system) Type and size of each component); design calculation of the feeding system (including design calculation of riser, cold iron and reasonable feeding channels); drawing (including casting drawings, casting process drawings, casting process cards, etc.) Draw and output). Compared with the traditional casting process design, the computer design casting process is characterized by accurate and rapid calculations, eliminating human error; it can store and utilize the experience of many founders in large quantities, enabling users to design more reasonable castings. Process; ability to optimize the casting process plan to determine the best solution; with the ability to automatically print records and draw various technical documents.
2. The numerical simulation technique of the solidification process uses the numerical calculation method to solve the mathematical discrete equation corresponding to the physical process of solidification forming, and the computer calculates the calculated result. This technology has been in existence for more than 30 years and has made great progress in the past 10 years. It has reached practical level in many aspects and has become one of the key technologies to improve the technical level of the foundry industry and the competitiveness of castings. The achievable goals are: predicting the setting time, unpacking time, determining the productivity; predicting the position and size of the shrinkage and shrinkage formation; predicting the surface and internal temperature distribution of the mold, facilitating the casting (especially the metal type) Design; control the solidification conditions, provide the necessary basis for the prediction of casting stress, micro and macro segregation, casting performance, etc. and analytical calculation data. The numerical simulation of the solidification process can not only visually display the liquid filling cavity and the process of cooling and solidification in the cavity, but also predict the possible defects, so it can comprehensively evaluate various process plans and parameters before the implementation of the manufacturing plan site. The technological scheme replaces or reduces the on-site trial production, which is especially outstanding for the production of solid shaped castings of large complex shapes or precious materials. Since the numerical simulation of the solidification process can reveal many physical essential processes, it also promotes the solidification theory. The development of microscopic microstructures of research and development in recent years can predict grain size and mechanical properties and is expected to be used in production in the near future.
3. Rapid Prototyping Manufacturing Technology This is a process of directly converting CAD design data into physical objects. It integrates CAD/CAM technology, modern numerical control technology, laser technology and new material technology. It requires traditional mold design and processing without drawings and elements. , greatly improving production efficiency. Rapid shape manufacturing techniques have been used to rapidly produce complex shapes in sand casting, investment casting, and solid casting, or to directly form coated sand into a mold using a laser beam to complete casting production. This high-tech is fundamentally changing the process of casting mold making in foundry production, showing high efficiency and high quality.
4. Computer control computer for casting process parameter detection and production process has been widely used as a control method for production process and solidification process. There are many casting production processes, relatively harsh working conditions, complicated influencing factors, and it is necessary to deepen in casting production. Research and extensive application of microcomputer detection and control technology. In recent years, there have been many examples of using computer to analyze changes in the production process, using computers to select the best parameters, adjust and control the production process, and automate the foundry production to achieve stable casting quality, increase labor productivity, and reduce casting costs. At present, a new generation of modeling production lines have been computer controlled, and computer-based automatic control systems have been used in processes such as melting, casting, sand processing, and quality inspection. The use of computer technology is a necessary condition for the production of high quality castings, and is also the main development direction of casting process control.
Simulation analysis and computer-aided engineering (CAE) applications can scientifically predict liquid metal filling processes, temperature and stress fields during solidification, and macroscopic defects and microstructure. It can optimize the commissioning process, ensure the quality of castings, shorten the trial production cycle, and improve competitiveness; it can achieve significant economic benefits while improving the production of castings. The application of computers in casting technology has played an unprecedented role in the following aspects.
1. Casting Process Computer Aided Design (CAD) technology mainly achieves the following functions, such as geometry and physical quantity calculation of castings (including calculation of casting volume, surface area, weight and thermal modulus); design calculation of casting system (including selection of casting system) Type and size of each component); design calculation of the feeding system (including design calculation of riser, cold iron and reasonable feeding channels); drawing (including casting drawings, casting process drawings, casting process cards, etc.) Draw and output). Compared with the traditional casting process design, the computer design casting process is characterized by accurate and rapid calculations, eliminating human error; it can store and utilize the experience of many founders in large quantities, enabling users to design more reasonable castings. Process; ability to optimize the casting process plan to determine the best solution; with the ability to automatically print records and draw various technical documents.
2. The numerical simulation technique of the solidification process uses the numerical calculation method to solve the mathematical discrete equation corresponding to the physical process of solidification forming, and the computer calculates the calculated result. This technology has been in existence for more than 30 years and has made great progress in the past 10 years. It has reached practical level in many aspects and has become one of the key technologies to improve the technical level of the foundry industry and the competitiveness of castings. The achievable goals are: predicting the setting time, unpacking time, determining the productivity; predicting the position and size of the shrinkage and shrinkage formation; predicting the surface and internal temperature distribution of the mold, facilitating the casting (especially the metal type) Design; control the solidification conditions, provide the necessary basis for the prediction of casting stress, micro and macro segregation, casting performance, etc. and analytical calculation data. The numerical simulation of the solidification process can not only visually display the liquid filling cavity and the process of cooling and solidification in the cavity, but also predict the possible defects, so it can comprehensively evaluate various process plans and parameters before the implementation of the manufacturing plan site. The technological scheme replaces or reduces the on-site trial production, which is especially outstanding for the production of solid shaped castings of large complex shapes or precious materials. Since the numerical simulation of the solidification process can reveal many physical essential processes, it also promotes the solidification theory. The development of microscopic microstructures of research and development in recent years can predict grain size and mechanical properties and is expected to be used in production in the near future.
3. Rapid Prototyping Manufacturing Technology This is a process of directly converting CAD design data into physical objects. It integrates CAD/CAM technology, modern numerical control technology, laser technology and new material technology. It requires traditional mold design and processing without drawings and elements. , greatly improving production efficiency. Rapid shape manufacturing techniques have been used to rapidly produce complex shapes in sand casting, investment casting, and solid casting, or to directly form coated sand into a mold using a laser beam to complete casting production. This high-tech is fundamentally changing the process of casting mold making in foundry production, showing high efficiency and high quality.
4. Computer control computer for casting process parameter detection and production process has been widely used as a control method for production process and solidification process. There are many casting production processes, relatively harsh working conditions, complicated influencing factors, and it is necessary to deepen in casting production. Research and extensive application of microcomputer detection and control technology. In recent years, there have been many examples of using computer to analyze changes in the production process, using computers to select the best parameters, adjust and control the production process, and automate the foundry production to achieve stable casting quality, increase labor productivity, and reduce casting costs. At present, a new generation of modeling production lines have been computer controlled, and computer-based automatic control systems have been used in processes such as melting, casting, sand processing, and quality inspection. The use of computer technology is a necessary condition for the production of high quality castings, and is also the main development direction of casting process control.
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