Numerical Simulation and Validation of Investment Casting Process of Bypass Valve Casting Based on MAGMA
The investment casting process of a bypass valve casting was numerically simulated and optimized by using MAGMA numerical simulation software.The casting defects such as porosity and cold shut caused by air entrainment and discontinuous liquid flow were predicted by analyzing the flow of the metal liquid into the mold cavity.On this basis,the position of the pouring cup was re-optimized,and the filling and solidification processes of the optimized process were simulated,and the location of the possible risk of porosity defects was predicted.The results show that after the process optimization,the metal liquid flow during the filling process is relatively stable,the sequential solidification of the casting is achieved,with no isolated liquid phase area,and it only has the risk of small shrinkage.In the actual trial production,package of insulation cotton was used in the runner and inner gate to solve the possible risk of shrinkage defects.The trial production castings were subjected to X-ray inspection and dissection verification,and no shrinkage,porosity and crack defects were found.The chemical composition and mechanical properties of the in-furnace samples meet the technical requirements,it shows that the investment casting process of the optimized bypass valve casting is reasonable.
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