Dissertation
Dissertation > Industrial Technology > Metallurgy and Metal Craft > Casting > Special Casting > Precision Casting

Estabishment of Foam Pattern Database and Research on Numerical Simulation of Lost Foam Casting

Author ZuoJianWei
Tutor YuYanDong
School Harbin University of Science and Technology
Course Materials Processing Engineering
Keywords Lost Foam Casting foam pattern database Numerical Simulation
CLC TG249.5
Type Master's thesis
Year 2014
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LFC is different to sand casting process because LFC have the existence ofthe foam pattern in the pouring process. The foam pattern quality will not onlyaffects the shape of the casting structure size, but also has a great impact on theinternal quality of castings. For LFC, the first to considerate is the overall shape.If sophisticated bubble shape can not be overall molded, we need to deal withfragmentation, which is directly affects efficiency and quality of production. Inthe pouring of LFC, high-temperature liquid metal makes it change like foamsoftening, melting, gasification, combustion and a series of physical andchemical reactions inside the sand mold.Large amounts of gas produced duringthe process makes filling and solidificating the liquid metal sand more complexthan Sand casting. The possibility of casting defects increasing and though hinderthe development of LFC. Numerical simulation techniques can predict defectsgeneration by simulating the proceswans of liquid metal filling and solidification.Therefore we can improve processing plan, and ultimately get the optimalsolution.We stored huge amounts of foam pattern cases in the database, it wasestablishing by VFP6.0management system. These cases are collected in thefactory production, establish three-dimensional modeling by Pro/E, outputimages, store in the database. It both provides a reference for the foam patternengineers. The basic requirement of database design is to provide a reference forthe user, store in their success cases inside and save for a long time.In the paper, we entity modeled the base mold parts by Pro/E three-dimensional software; Though ProCAST numerical simulation software, we simulated the filling process. We can see the filling was stable and porosityshrinkage defects focus on the riser location. So we can come to the conclusionthat the program is reasonable, actual production meets the requirements and thusverify the reliability of the numerical simulation.

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