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基于ProCAST的叶轮铸件铸造工艺优化.docx

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基于ProCAST的叶轮铸件铸造工艺优化 Title:ProcessoptimizationofimpellercastingbasedonProCAST Abstract: Castingisawidelyusedmanufacturingmethodforproducingcomplexshapedparts,suchasimpellers.Theoptimizationofthecastingprocessiscrucialtoenhancethequalityandperformanceofthecastedparts.ThispaperfocusesontheprocessoptimizationofimpellercastingusingtheProCASTsoftware.Theaimistoimprovetheefficiencyandreliabilityofthecastingprocess,ultimatelyleadingtobetterproductquality. Introduction: Impellersarekeycomponentsinvariousindustries,includingautomotive,aerospace,andpowergeneration.Thesecomponentsplayacriticalroleinfluidflowandsystemefficiency.Thequalityofimpellersdependsonthecastingprocess,asdefectssuchasporosity,shrinkage,andhottearscansignificantlyaffectperformanceanddurability.Therefore,itisessentialtooptimizethecastingprocesstominimizethesedefects. Methodology: TheProCASTsoftwareisapowerfultoolforsimulatingandoptimizingcastingprocesses.Itutilizesadvancednumericalalgorithmstopredictthebehaviorofthemetalduringsolidification,filling,andcoolingstages.Thisenablesengineerstoidentifypotentialdefectsandoptimizeprocessparameterssuchaspouringtemperature,molddesign,andgatingsystem. Results: ByanalyzingthesimulationresultsobtainedfromProCAST,severaloptimizationscanbemadetoimprovethecastingprocess.Firstly,thepouringtemperaturecanbeadjustedtoensureproperfillingofthemoldandminimizetheoccurrenceofdefectslikecoldshuts.Secondly,thedesignofthegatingsystemcanbeoptimizedtocontroltheflowofmoltenmetalandavoidtheformationofturbulenceorairentrainment.Lastly,theselectionofthemoldmaterialanddesigncaninfluencethecoolingrateandreducetheriskofshrinkageorhottears. Discussion: TheoptimizationprocessusingProCASTallowsforacomprehensiveevaluationofdifferentcastingparametersandtheireffectonthefinalproductquality.Byiterativelyadjustingtheprocessparametersandevaluatingthesimulationresults,theoptimalcombinationthatminimizesdefectscanbedetermined.Additionally,thesimulationresultsprovideinsightintothesolidificationandcoolingbeha