NUMERICAL SIMULATION AND PROCESS OPTIMIZATION ON CAST STEEL BEARING SLEEVE

A three-dimensional Computer Aided Design (CAD) model of the bearing sleeve casting is established by Pro/E software. The ViewCast program is utilized for studying casting processes of solidification and mould-filling in order to optimize the casting technology. Based on the solidification simulation, the casting shrinkage and porosity as well as solidification processes are forecast visually in diagrams with the help of ViewCast. The mould-filling simulation results verify whether the fluid/liquid metal fills gates and the mould smoothly. The simulation results of an initial casting scheme show that this scheme is improper. Two optimization schemes have been completed based on the filling simulation so that a modified casting technology is obtained. The simulation results of optimized schemes indicate that the metal fluid fills the mold smoothly and the shrinkage is eliminated effectively. The optimized scheme II is preferred to scheme I. Experimentally, the casting confirms that these optimized methods are very useful in reducing the casting defects and improving the product quality.