华中科技大学材料学院 华铸CAE/InteCAST-铸造工艺分析软件集成系统

华铸CAE/InteCAST-中国铸造领域著名的模拟分析系统,是华中科技大学经20年的研究与开发,并在长期的生产实践检验中不断改进、完善起来的一项软件系列产品。华铸CAE/InteCAST铸造工艺分析软件集成系统是分析和优化铸件铸造工艺的重要工具,它以铸件充型过程、凝固过程数值模拟技术为核心对铸件进行铸造工艺分析。可以完成多种合金材质(包括铸钢、球铁、灰铁、铸造铝合金、铸造铜合金等)、多种铸造方法(砂型铸造、金属型铸造、压铸、低压铸造等)下铸件的凝固分析、流动分析以及流动和传热耦合计算分析。实践应用证明,本系统在预测铸件缩…     

华中科技大学材料学院——华铸CAE／InteCAST-铸造工艺分析软件集成系统

华铸CAE/InteCAST-中国铸造领域著名的模拟分析系统，是华中科技大学经20年的研究与开发，并在长期的生产实践检验中不断改进、完善起来的一项软件系列产品。华铸CAE/InteCAST铸造工艺分析软件集成系统是分析和优化铸件铸造工艺的重要工具，它以铸件充型过程、凝固过程数值模拟技术为核心对铸件进行铸造工艺分析。可以完成多种合金材质（包括铸钢、球铁、灰铁、铸造铝合金、铸造铜合金等）、多种铸造方法（砂型铸造、金属型铸造、压铸、低压铸造等）下铸件的凝固分析、流动分析以及流动和传热耦合计算分析。     

铸造CAE技术及其在消失模与V法铸造中的应用

随着计算机硬件条件的改善和铸造CAE技术的发展,铸造CAE软件在实际生产中起着越来越重要的作用。本文介绍了铸造CAE技术的基本思路和原理;并给出了华铸CAE款件在消失模与V法铸造中的一些应用实例,应用表明现阶段的铸造CAE软件能够准确地预测铸件在充型凝固过程中可能产生的缺陷．从而辅助工艺人员进行工艺优化,指导实际铸件生产。     

铸造CAE技术在熔模铸造中的应用

介绍了铸造CAE技术的基本思路和原理;并给出了华铸CAE软件在熔模铸造中的一些应用实例,应用表明现阶段的铸造CAE软件能够准确地预测熔模精密铸件在充型凝固过程中可能产生的缺陷,从而辅助工艺人员进行工艺优化,指导实际熔模精密铸件生产.     

华铸CAE／InteCAST铸造工艺分析软件集成系统

华铸CAE／InteCAST中国铸造领域著名的模拟分析系统,是华中科技大学经20年研究开发,并在长期生产实践检验中不断改进、完善起来的一项软件系列产品。该软件集成系统是分析和优化铸件铸造工艺的重要工具,它以铸件充型过程、凝固过程数值模拟技术为核心对铸件进行铸造工艺分析。可完成多种合金材质(包括铸钢、球铁、灰铁、铸造铝合金     

低压铸造CAE软件的开发及应用

介绍了低压铸造数值模拟的原理、思路以及低压铸造CAE的应用,并给出了一个铝合金蜗壳铸件和汽车轮毂的低压铸造应用实例。采用华铸CAE低压模块对低压铸件充型凝固过程进行模拟的结果与实际符合较好。实际应用表明,低压铸造CAE能有效地评判低压铸造工艺设计的合理性,提高工艺设计效率。     

主动轮的铸造工艺优化与实践验证

针对两种主动轮铸件批量出现缩松情况,运用华铸CAE软件对传统的铸造工艺进行凝固模拟和分析.在凝固模拟计算结果与实际相一致的基础上,采用华铸CAE软件对传统铸造工艺进行了优化,确定了主动轮类铸件较合适的铸造工艺方案,并得到了实践验证.     

钛合金离心铸造数值模拟技术及应用

铸造CAE在复杂钛合金铸件的离心铸造凝固过程模拟,预测了钛合金铸件铸造过程的可能缺陷。简要介绍了复杂钛合金离心铸造过程数值模拟技术,包括钛合金的充型凝固模拟、凝固过程温度场数值模拟及预测缩松缩孔等,并给出了华铸CAE软件对典型的复杂钛合金支板铸件进行模拟和模拟结果分析的应用案例。应用表明,该软件能够准确地预测钛合金铸件可能产生的气孔、缩松缩孔等缺陷等。     

主动轮的铸造工艺优化与验证

针对本厂生产的两种主动轮铸件批量出现缩松情况,运用华铸CAE软件对传统的铸造工艺进行凝固模拟和分析.在凝固模拟计算结果与实际相一致的基础上,采用华铸CAE软件对传统铸造工艺进行了优化,确定了主动轮类铸件较合适的铸造工艺方案,并得到了实践验证.     

天然气压缩机机体铸件的凝固模拟及工艺优化

机体铸件是天然气压缩机组的关键部件之一。文章根据基体铸件的技术要求,结合铸造厂的实际生产条件,讨论了基体铸件的铸造工艺方案和浇注系统,并使用华铸CAE／InteCAST进行了凝固模拟分析和工艺优化。所得结果适用于实际生产。     

The development status of foundry industry in Chinese Zhejiang province

1. General introduction Zhejiang province is one of the most developed regions in Chinese foundry industry. There are more than 4 000 foundries there. Among them there are over 20 foundries whose annual output of castings exceeds ten thousand tons, and most of them are medium- or small-sized foundries.The annual output of castings in the entire province exceeds 1 850 000 tons, and more than100 000 tons are exported. There are approx.100 000 practitioners in the Province.     

中小汽车铸件生产厂的技术改造途径

综合分析了国内中小汽车铸件生产企业的现状与问题，探讨了国内中小汽车铸件生产厂需要技术改造的必要性和迫切性。认为：做好形势分析，明确产品定位，整体规划，分步实施，工艺装备与检测手段配套，提高高附加值铸件的比例，建立完善的人才队伍和质量保证体系，延伸供应链，对铸件深加工等，是中小汽车铸件生产厂发展改造、提高经济效益的可行途径。     

3D打印快速制造铝合金传动箱箱体

介绍了3D打印技术生产传动箱箱体铸件过程,通过模拟CAD/CAE优化传动箱箱体铸件毛坯结构和铸造工艺,采用3D打印SLS技术制作的铝合金箱体蜡型和石膏型电磁真空增压铸造工艺融合得到满足尺寸和性能要求的合格铸件.     

State of the Art Treatment of Non-Ferrous Castings 3-in-l Heat Treatment Systems Combine Foundry Processes

1.Aluminum Casting Production Now andThenIt is well known that the reduction of the total weightof an automobile leads to a reduction in fuelconsumption(about0.5liters of100kilometers).Thisimproved fuel economy also reduces the CO2emissionsreleased into the atmosphere.As the size of vehicleshas grown,the overall weight has had to be decreased.The automotive industry is therefore using more andlighter metal components in order to reduce fuelconsumption and lower emissions.Production of cylin…     

State of the Art Treatment of Non-Ferrous Castings 3-in-1 Heat Treatment Systems Combine Foundry Processes

The interior of a high-pressure die-casting is of an unsatisfactory quality. Engine blocks made with this die casting process show lower specific engine performance. Pressure die-casting can hardly be heat treated for obvious reasons PSM (Precision Sand Molds) process uses sand and organic binder to generate a mold and even allows the manufacturing of complex diesel engine blocks in aluminum alloys. Combined technologies are available for semi-permanent mold castings with cores and castings made in Precision Sand Molds with organic binders. Castings are placed into the special heat treatment furnace immediately after pouting without the operations in stand alone machinery. This patented Sand Lion^R 3-in-1 technology processes hot castings and carries out three (3) foundry processes simultaneously in one (1) automated machine: 1) De-coring and sand removal; 2) Thermal sand reclamation; 3) Solution heat treatment of castings. The combination of several main casting processes is reflected in significant reductions of energy consumption, of production costs, and improving the quality of the castings. Audits in foundries using the 3-in-1 process showed an average reduction in production costs of more than 30%.     

并行工程环境下的铸造工艺CAD/CAE系统

在并行工程环境下集成铸造工艺ＣＡＤ／ＣＡＥ系统,能高效率、高质量地实现铸造工艺的设计－－校核－－再设计－－优化的技术路线,从而有力地支持产品的并行设计,以统一的造型平台ＳｏｌｉｄＥｄｇｅ作为信息交换的基础,将集成铸造工艺ＣＡＤ／ＣＡＥ系统纳入了并行工程环境。集成系统以产品模型作为输入,进行铸造工艺参数设计,浇冒口系统设计,生成包含铸造工艺信息的铸件三维模型,通过凝固过程数值模拟,校和优化工艺设计。     

Gating and risering in vertical green sand moulds

The high number of successful green sand foundries working with vertical moulding equipment is the best proof of the advantages of this technology. It provides high productivity and accurate positioning of cores. It offers the freedom to design and produce with optimal functioning gating systems to secure good casting quality.

The aim of the paper is to look into new ways of improving this successful casting technology. First a short introduction to the advantages of vertical moulding will be presented.

The next subject is the advantages of utilising casting process simulation to optimise casting layout, gating and risering. Focus is on castings produced in the conventional way as well as on castings that are produced using the newly developed active feeding and active bottom filling technique.

The last subject is to investigate if this new active feeding technique could be used for iron castings too. Experimental casting trials, as well as numerical simulation results, indicate that it is also functioning for iron castings; so the limiting factor will be the availability of robust equipment, which can keep up with the very fast vertical moulding machines.     

缸体、缸盖铸件生产的总体工艺路线——车用中小型发动机灰铸铁缸体缸盖铸件生产工艺(1)

介绍发动机缸体、缸盖铸件生产的总体工艺路线.目前大多数汽车发动机铸件生产企业都采用冲天炉-电炉双联熔炼,为防止铁液晶核减少、过冷度增加、白口化倾向较大,应控制电炉熔炼温度,避免长时间过热和保温;为确保铸件尺寸精度,铸型宜采用高密度造型,也可以采用呋喃树脂砂型或PEP-SET树脂砂型.根据国内目前情况,建议主体砂芯采用冷芯工艺,而水套等部位的砂芯采用覆膜砂工艺更为稳妥可靠.     

Benchmarking commercial aluminium sand gating systems

The results of a study to identify the range of commercial gating systems used in American aluminium foundries are reported. Fifteen foundries using green sand moulding methods participated in the study by producing moulds of test castings using their “normal” shop gating systems. The foundries were asked to rig a common test pattern for a target volume of 1,500 pieces per month, produced to a “commercial” quality standard, and with an absence of visible porosity on machined surfaces. Information was also requested on essential melt and moulding media conditions, as well as a selling price for the castings.

The evaluations included gating ratio and yield measurements, radiographic evaluations of subsurface quality, machining of cope and drag surfaces to reveal gating induced trapped air and dross, pressure testing of two drilled bosses, and a final liquid penetrant examination of the machined surfaces.

Those features in the individual systems that appeared to produce the best results are summarised, as well as some undesirable practices that might have a negative influence upon casting quality.     

CY-61100车床床身铸造过程数值模拟及仿真优化研究

对铸造充型及凝固过程数值模拟的教学模型进行了研究.通过铸造过程CAE仿真优化技术与传统铸造工艺设计有效结合,对CY-61100车床床身的铸造工艺进行了优化设计,在工厂实际浇注生产应用中取得了良好效果.