NUMERICAL SIMULATION AND OPTIMIZATION OF THE CASTING PROCESS OF A CASTING-STEEL WHEEL

The mechanism of formation and the regularity of shrinkage distribution in a cast-steel wheel were simulated by computer methods. SolidWorks software package was used to produce a three-dimensional model of the cast parts, and Experto ViewCast software package was employed to simulate the casting process. The simulated results show that the mold filling was smooth and thus no splashing occurred. However, shrinkage and porosity appeared at the transition phase between the wheel-rim and web during the process of solidification. The reason for that is the imperfect solidification sequence. The fast cooling rate in the final thin web position led to the block of feeding channel at the transition area. The foundry technique was improved successfully by computer-aided methods. The volume of shrinkage was reduced by applying an insulating material, which made the castings solidify progressively as designed. The performance of the wheel produced by the improved technology agreed very well with the technical requirements.