Investigation of the Spillability of the Casting Mold in the Design of the Gating System of the Body Casting

The purpose of the study is to determine the size and configuration of the gating system to prevent gross defects of castings associated with insufficient mold spillage when obtaining the body casting by the casting method.

Methods. The research was carried out using computer modeling of the casting process based on the finite element method and virtual engineering.

To achieve this goal, a 3D model of the casting with several variants of the gate system was built. Modeling of the casting process was carried out in the PROCAST software package, when working in which drawing defects were automatically eliminated and 2D and 3D grids were built, which allows you to take into account the casting configuration as much as possible during the modeling process. As a result of the simulation of the casting process, diagrams of filling the mold with melt were constructed and the places of possible gross defects were determined.

Results. Based on the results of computer modeling of the casting process for the body models with different configurations and sizes of the gating system, the variants of the gating system were determined to ensure the absence of gross defects associated with insufficient mold spillage. The uniformity of the casting crystallization process was also taken into account.

Conclusion. The use of modern computer modeling methods can significantly reduce the time of technological preparation of production, promptly make changes to the configuration of castings and gate systems, predict the appearance of possible defects and promptly develop measures to eliminate them. The widespread use in engineering practice of software complexes modeling various foundry processes makes it possible to improve the quality of manufactured products and their competitiveness.

1. Yakovlev A. D., Pustovalov D. O., Ovchinnikov A. M. Optimizatsiya litnikovo-pitayushchei sistemy dlya otlivki "Korpus" s primeneniem 3D tverdotel'nogo modelirovaniya i sistemy PROCAST [Optimization of Gating-feeding system for the casting of a "Case" with the use of 3D solid modeling and system PROCAST]. Master's Journal, 2013, no. 1, рр. 37–41.

2. Duyunova V. A., Molodtsov S. V., Leonov A. A., Trapeznikov V. A. Primenenie metodov komp'yuternogo modelirovaniya pri izgotovlenii slozhnokonturnoi otlivki [Application of computer simulation techniques in the manufacture of selenocentric castings]. Trudy VIAM = Works of VIAM, 2019, no. 11 (83), рр. 3–11.

3. Bondarenko Yu. A., Echin A. B., Bazhenov V. E., Koltygin A. V. Komp'yuternoe modelirovanie raspredeleniya temperatury na poverkhnosti formy i vnutri otlivki pri vysokogradientnoi napravlennoi kristallizatsii [Computer modeling of the temperature distribution on the mold surface and inside the casting with highly gradient directed crystallization]. Izvestiya vysshikh uchebnykh zavedenii. Tsvetnaya metallurgiya = Izvestia of higher educational institutions. Non-ferrous metallurgy, 2017, no. 4, pp. 53–61.

4. Tonkovich A. A., Skvortsov A. A. Raschet vertikal'nykh litnikovykh sistem s ispol'zovaniem standartnykh elementov [Calculation of vertical gate systems using standard elements]. Lit'e i metallurgiya = Casting and metallurgy, 2016, no. 1 (82), pp. 136–150.

5. Bazhenov V. E. Ob osobennostyakh rascheta usadochnykh defektov v otlivkakh s ispol'zovaniem programmnogo paketa PROCAST [On the features of calculating shrinkage defects in castings using the PROCAST software package]. Izvestiya vysshikh uchebnykh zavedenii. Tsvetnaya metallurgiya = Izvestiya vse. Non-ferrous metallurgy, 2009, no. 5, pp. 36–38.

6. Starikov V. S., Zubkova O. S., Zubkov D. A.. Modelirovanie protsessa lit'ya v obolochkovuyu formu dlya detali "korpus" v SAPR SOLIDWORKS [Modeling of the process of casting into a shell mold for the "housing" part in CAD SOLIDWORKS]. Sovremennye materialy, tekhnika i tekhnologii = Modern materials, equipment and technologies, 2019, no. 6 (27), pp. 23–26.

7. Suslova I. V. [Modeling of linear pouring and crystallization processes using PROCAST software]. Aktual'nye voprosy sistem kachestva i ekologizatsii proizvodstva. Materialy Vserossiiskoi nauchno-prakticheskoi konferentsii [Current issues of quality systems and greening of production. Materials of the All-Russian Scientific and practical Conference]. Kurgan, Kurgan. Univ. Publ., 2020, pp. 190–192. (In Russ.)

8. Pustovalov D. O. Optimizatsiya konstruktsii pribylei dlya stal'nykh otlivok slozhnoi konfiguratsii s posleduyushchim analizom v programmnom komplekse PROCAST [Optimization of the profit structure for steel castings of complex configuration with subsequent analysis in the PROCAST software package]. Vestnik Permskogo natsional'nogo issledovatel'skogo politekhnicheskogo universiteta. Mashinostroenie, materialovedenie = Bulletin of the Perm National Research Polytechnic University. Mechanical engineering, materials science, 2012, vol. 14, no. 3, pp. 63–67.

9. Perfilova V. Yu., Shirokikh E. V. Snizhenie urovnya braka otlivok s pomoshch'yu komp'yuternogo modelirovaniya liteinogo protsessa v PROCAST [Reduction of the level of castings defects using computer modeling of the casting process in PROCAST]. Kompleksnye problemy razvitiya nauki, obrazovaniya i ekonomiki regiona = Complex problems of the development of science, education and economy of the region, 2014, no. 2 (5), pp. 106–111.

10. Trapeznikov N. V., Shumkov A. A., Matygullina E. V. Matygullina E. V. Matematicheskoe modelirovanie napryazhenno-deformirovannogo sostoyaniya keramicheskogo sterzhnya v protsesse prokalki [Mathematical modeling of the stress-strain state of a ceramic rod during calcination]. Teoriya i tekhnologiya metallurgicheskogo proizvodstva = Theory and technology of metallurgical production, 2020, no. 4 (35), pp. 29–34.

11. Nikanorov A. V. Sravnitel'nyi analiz komp'yuternykh programm dlya modelirovaniya liteinykh protsessov [Comparative analysis of computer programs for modeling foundry processes]. Vestnik Irkutskogo gosudarstvennogo tekhnicheskogo universiteta = Bulletin of the Irkutsk State Technical University, 2018, vol. 22, no. 11 (142), pp. 209–218.

12. Batyshev K. A., Katelin V. A., Semenov K. G., Pankratov S. N., Koloskov S. V., Vasiyarov A. V. Ispol'zovanie sovremennykh sistem modelirovaniya i kontrolya dlya proizvodstva otlivok otvetstvennogo naznacheniya [The use of modern modeling and control systems for the production of castings of responsible purpose]. Sovremennye materialy, tekhnika i tekhnologii = Modern materials, equipment and technologies, 2018, no. 1 (16), pp. 4–10.

13. Rodionova M. P. Rekomendatsii po ustraneniyu defektov pri lit'e po vyplavlyaemym modelyam [Recommendations for the elimination of defects in casting by melting models]. Aktual'nye problemy aviatsii i kosmonavtiki = Actual problems of aviation and cosmonautics, 2016, vol. 2, no. 12, pp. 202–203.

14. Vdovin K. N., Feoktistov N. A., Ovchinnikova M. V. Komp'yuternoe modelirovanie fizicheskogo pitaniya otlivki "koleso" v lit'e po vyplavlyaemym modelyam [Computer modeling of the physical power of the casting "wheel" in casting by smelted models]. Tekhnologii metallurgii, mashinostroeniya i materialoobrabotki = Technologies of metallurgy, mechanical engineering and material processing, 2018, no. 17, pp. 98–101.

15. Leushina L. I., Ulyanov V. A., Nischenkov A. V. Innovatsionnye tekhnicheskie resheniya povysheniya treshchinostoikosti obolochkovykh form lit'ya po vyplavlyaemym modelyam [Innovative technical solutions for increasing the crack resistance of shell casting forms according to smelted models]. Teoriya i tekhnologiya metallurgicheskogo proizvodstva = Theory and technology of metallurgical production, 2013, no. 1 (13), pp. 48–49.

16. Lit'e po vyplavlyaemym modelyam [Casting by smelted models]; ed. by Ya. I. Shklennik and V. I. Ozerov. 2th ed., revised and supplemented. Moscow, Mashinostroenie Publ., 1971. 436 p.

17. Kumanin I. B. Liteinoe proizvodstvo [Foundry production]; ed. by I. B. Kumanin. Moscow, Mashinostroenie Publ., 1971. 319 р.

18. Ozerov, V. A., Garanin V. O. Lit'e povyshennoi tochnosti po razovym modelyam [Casting of increased accuracy according to one-time models]. Moscow, Vyshaya shkola Publ., 1988. 85 р.

19. Zubkova O. S., Starikov V. S., Zubkov D. A., Bolotov S. S. [The main stages of modeling the casting process by melting models of the body billet in the PROCAST software package]. Tekhnika i tekhnologii: puti innovatsionnogo razvitiya. Sbornik nauchnykh trudov 9-i Mezhdunarodnoi nauchno-prakticheskoi konferentsii [Technique and technology: ways of innovative development. Collection of scientific papers of the 9th International Scientific and Practical Conference]. Kursk, Universitetskaya kniga Publ., 2020, pp. 185–190. (In Russ.)

20. Abdullin A. D. Novye vozmozhnosti programmnogo kompleksa PROCAST 2017 v oblasti modelirovaniya liteinykh protsessov [New capabilities of the PROCAST 2017 software package in the field of modeling foundry processes]. Metallurg = Metallurg, 2017, no. 6, pp. 20–25.

21. Kuchin P. S. Ispol'zovanie programmnogo kompleksa PROCAST [Using the PROCAST software package]. Liteinoe proizvodstvo = Foundry production, 2007, no. 7, pp. 27–30.