Process Design and Regulation of Brake Casting Based on Real Casting Numerical Calculation

Author of the article:DU Zunzhong1 , XU Zhe2 , SHI Xiao2 , CHEN Xuan1 ,YUAN Yuedong1 , ZHANG Guoqun1 , LIU Kun1 , CHEN Zhe

Key Words：exhaust brake valve; lost foam casting; numerical simulation; casting defects

Abstract：Taking butterfly valve for exhaust brake as the research object, through the analysis of the shape, structure and material of valve body, a reasonable casting process scheme was put forward by using lost mold casting method. Numerical simulating of the valve precision casting process was conducted based on the ProCAST software. The flow, temperature field, solid rate distribution and defect distribution of the valve casting during mold filling and solidification were studied, and the process was optimized according to the simulation results. The results show that the defects of shrinkage cavity and porosity are effectively controlled and the volume of defects is reduced by more than 42% after improvement of casting system. Through casting simulation, the production practice of butterfly valve for exhaust brake is effectively guided, optimizing the production process and also saving the production cost