Numerical simulation of the mold filling process of the brake lever for an electric multiple unit

Abstract

Abstract The brake lever for an electric multiple unit (EMU) of a train is an important supporting component that directly affects the usability and safety of EMU. In this study, the mold filling, solidification, and shrinkage processes of the brake lever of the EMU were simulated using Anycasting software, and the distributions of the mold filling speed, mold filling temperature, and shrinkage defects were analyzed. The results show that the brake lever for the EMU exhibits casting defects such as shrinkage porosity and shrinkage cavities. To eliminate these casting defects, a chilled-iron process was developed; however, the appearance of cementite increased the brittleness of the castings, which deteriorated their strength and plastic toughness. Hence, a snap-chilling sheet process was designed to fabricate the brake lever for the EMU, and a numerical simulation of the process was performed using the Anycasting software. The shrinkage defects of the castings were effectively eliminated; simultaneously, the cementite disappeared, and the microstructure of the thick parts of the brake lever showed no obvious changes. The prepared brake lever satisfied the requirements of the EMU.