阶梯轴铸钢件的铸造工艺设计及数值模拟
Design and Numerical Simulation of Casting Process for Steel Multi-diameter Shaft Casting
米国发， 陈立林， 王海燕，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：阶梯轴；数值模拟；凝固过程；铸造工艺
英文关键字：multi-diameter shaft; numerical simulation; solidification process; casting process
中文摘要：对阶梯轴铸钢件进行铸造工艺方案设计，包括分型面和浇注位置的选择，各项铸造工艺参数的确定以及浇注系统、冒口、冷铁的设计。根据铸件形状与结构特点，采用中注式浇注系统，内浇道放置在轴后的端面，并用一个内浇道对铸件进行浇注。将铸件划分为4个补缩区域进行冒口设计，并配合冷铁使用来实现铸件的顺序凝固。建立铸件的三维模型，并运用ViewCast铸造模拟软件对铸件的凝固过程进行了模拟计算。初次模拟显示，在阶梯轴的凸台处与其临近连接的阶梯轴段会产生缩孔、缩松缺陷。根据数值模拟结果并结合理论分析，对铸造工艺方案进行了优化设计。通过增大冒口尺寸和高度、增设冷铁的方法，有效地消除了铸造缺陷，从而获得了合理的铸造工艺方案。
英文摘要：The casting process for steel multi-diameter shaft casting were designed. In view of casting characteristics and shape, the parting gate system was defined. In order to obtain directional solidification sequence, the casting was divided into 4 positions to calculate the volume of the risers and the chills. The 3-D model of the casting was built by CAD software and the solidification process was simulated by ViewCast software. The initial simulation indicated that the shrinkage defects formed at the boss sections and the section near the connection of multi-diameter shaft. According to the results and combining theoretical analysis, the casting process was optimized. By increasing the size of risers and the numer of chills, the defects are eliminated effectively, the reasonable casting process is obtained.