Iterative reverse deformation optimization design of castings based on numerical simulation of solidification thermal stress

In the casting process, in order to compensate for the solidification shrinkage to obtain higher dimensional accuracy of the casting, it is often necessary to modify the original design of castings, and a suitable compensation method has a decisive impact on the dimensional accuracy of the actual casting. In this study, based on solidification simulation, a design method of reverse deformation is proposed, and two compensation methods, empirical compensation and direct reverse deformation, are implemented. The simulation results show that the empirical compensation method has problems such as difficulty in determining the parameters and satisfaction of both the overall and local accuracy at the same time; while based on the simulation results for each node of the casting, the direct reverse deformation design achieves the design with shape. In addition, the casting model can be optimized through iterative revisions, so that higher dimensional accuracy can be continuously obtained in the subsequent design process. Therefore, the direct reverse deformation design is more accurate and reasonable compared to empirical compensation method.