Evaluate the Effectiveness of Casting and Feeding Systems

When laying out the rigging system, a common question is how to evaluate the effectiveness of the measures taken. What effect, for instance, does choosing a larger feeder or changing the position of a chill have on the feeding process? By systematically making use of virtual designs of experiments, it is possible to answer these questions.

In Figure 1, you can see the rigging system of a ductile iron casting (EN-GJS-400) with possible positions of the chills and feeders including different feeder sizes. The simulation of a virtual test field does not only provide you with information about the best chill layout, feeder size and position, but also allows you to see which effect the varied variables have on the casting quality.

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热处理工艺的虚拟优化可以:

  • 减少炉内的工艺时间
  • 评估热处理的需求以满足金相、残余应力分布或机械性能的要求
  • 分析工艺变化对金相和材料性能的影响
  • 尽量减小热处理过程中的铸件变形
  • 减少大量试验的成本和开发时间

虚拟试验可以实现铸钢件回火温度和时间的系统变化,以找到强度和延展性之间的最优平衡。

可计算铸造过程中残余应力的释放,例如可以进行铸铁件的去应力退火。在铸铁中,除了常规去应力退火和珠光体化外,还可以优化复杂生产工艺,以生产出奥贝球铁(ADI)。

对于由铝合金的结构件,除了其他方面外,还可借助于热处理过程中残余应力计算对热处理支座的设计进行优化。

通过相应的工艺和设计优化,可以将由于铸件淬火时较高的温度梯度导致裂纹的风险降到最小。

用户案例(热处理)

固溶处理过程中的铸件变形

铝铸件通常经过热处理,以提高机械性能,同时降低铸造过程中产生的热应力。

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