Numerical Simulation and Process Optimization of Casting Process of ZL114A Beam

Author of the article:SUN Ce1 , SHENG Wenbin2 , YAN Sijin1 , ZHANG Zhenbo1 , CHEN Zongmin1

Author's Workplace：1. School of Mechanical Engineering, Shandong University of Technology, Zibo 255049, China; 2. Center of Forecasting and Analysis, Shandong University of Technology, Zibo 255049, China

Key Words：ZL114A; sand mold gravity casting; slot casting system; casting simulation

Abstract：The structural analysis of the aluminum alloy beam was carried out and the casting process was designed. The simulation process of the casting process was carried out by using AnyCasting software. The influence of riser form and chill position on the solidification process of casting and the probability of defect generation was analyzed. Based on this, the casting process was optimized. The results show that when the filling temperature is 710 ℃ and the filling speed is 115 mm/s, the temperature distribution inside the casting is uniform and the probability of overall defects is low. However, due to the thin wall thickness and complex internal structure of the casting, it is easy to produce hot joints in many positions, especially the working surface ladder area of the casting and the joint position between the ribbed plate and the wall, and the probability of shrinkage and loosening defects in these positions during solidification is also large. According to the simulation results, the defects of the side wall of the casting are eliminated in a way that a subsidy is led out at the riser, and the chill is placed at the bottom. The optimized scheme significantly reduces the probability of defects.