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对阶梯轴铸钢件进行铸造工艺方案设计,包括分型面和浇注位置的选择,各项铸造工艺参数的确定以及浇注系统、冒口、冷铁的设计。根据铸件形状与结构特点,采用中注式浇注系统,内浇道放置在轴后的端面,并用一个内浇道对铸件进行浇注。将铸件划分为4个补缩区域进行冒口设计,并配合冷铁使用来实现铸件的顺序凝固。建立铸件的三维模型,并运用ViewCast铸造模拟软件对铸件的凝固过程进行了模拟计算。初次模拟显示,在阶梯轴的凸台处与其临近连接的阶梯轴段会产生缩孔、缩松缺陷。根据数值模拟结果并结合理论分析,对铸造工艺方案进行了优化设计。通过增大冒口尺寸和高度、增设冷铁的方法,有效地消除了铸造缺陷,从而获得了合理的铸造工艺方案。
The design of the casting process for the stepped shaft castings includes the selection of the parting surface and casting position, the determination of various casting process parameters and the design of casting system, riser and chilled iron. According to the shape and structure of the casting, the injection molding system is used. The runner is placed on the rear face of the shaft, and an ingate is used to cast the casting. The castings are divided into four feeding areas for riser design, and with the use of cold iron to achieve the order of solidification castings. The three-dimensional model of the casting is established and the casting process is simulated by using ViewCast casting simulation software. The first simulation shows that stepped shaft sections adjacent to the bosses of the stepped shaft produce shrinkage cavities which cause defects. According to the numerical simulation results and the theoretical analysis, the casting process scheme was optimized. By increasing the size and height of riser, the method of adding chill iron can effectively eliminate the casting defects and obtain a reasonable casting process scheme.