Process Simulation and Improvement of Ultra-large Magnesium Alloy Aircraft Pod Casting Based on ProCAST
Aiming at the shrinkage casting problem occurred frequently at the rounded corner of a ultra-large magnesium alloy aircraft pod thin-wall casting,firstly,the defect causes were analyzed from the casting structure,alloy materials and casting technology,and the scheme of adding ingates in the existing pour system and optimizing the ingate geometry was proposed to enhance the feeding capacity of the riser for the defective zone and inhibit the introduce of inclusions.Then,the casting finite element simulation method was used to conduct the simulation analysis of the optimized casting process,including the flow field and temperature field,solid phase rate and temperature cloud map slice,etc,and the feasibility of the optimized scheme was determined.Finally,the casting test verification was carried out.The results show that the optimized process successfully solves the shrinkage defect at the rounded corner of the ultra-large magnesium alloy thin-wall casting.The research has practical significance for designing and optimizing other ultra-large magnesium alloy thin-wall castings.
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