Numerical Simulation and Optimization on Casting Process of Mould Clamping Board Using a Nodular Cast Iron

Abstract

A three-dimensional Computer Aided Design (CAD) model of the mould clamping board is established by Pro/E software. The ViewCast program is utilized to study casting processes of solidification and mould-filling in order to design the risers and optimize the casting technology. Based on the solidification simulation, the casting defects such as shrinkage and porosity are forecasted visually in diagrams with the help of ViewCast. Reasonable risers are designed on the basis of the solidification simulation. The mould-filling simulation verify the metal fluid gates the mould smoothly and reposefully. The filling simulation results of initial casting scheme show that this casting technology is improper. The optimized scheme is completed through the filling simulation and a modified casting technology is obtained. The parting gating system is used to pouring the mold of clamping board. The simulation results of optimized scheme indicate that the shrinkage are eliminated effectively and the metal fluid fill the mold smoothly. Experimentally, the casting confirms that the optimized method is very useful in reducing the casting defects and improving the product quality.