Numerical Simulation of Solidification Process and Optimization for High-Strength Corrugated Plate by Lost Foam Casting

To solve the defects such as turbulent filling, incomplete decomposition of foam patterns, shrinkage porosity and cavities in the lost foam casting of high-strength corrugated plates, this paper adopts numerical simulation software to carry out simulation analysis and parameter optimization of the casting process. Combined with the structural characteristics of the casting, three initial pouring schemes are designed, including stepped middle-injection vertical placement (Scheme A), stepped middle-injection horizontal placement (Scheme B), and stepped side-injection (Scheme C). The filling flow characteristics, temperature field distribution and solidification defect distribution rules of different schemes are systematically compared. The simulation results show that Scheme A presents obvious turbulence and gas entrapment during metal liquid filling with poor flow stability. The filling process of Scheme B and C is relatively stable, but all three initial schemes have varying degrees of shrinkage porosity and cavities. Specifically, the defects of Scheme B are widely distributed on the surface of the casting, while Scheme C suffers from incomplete decomposition of foam patterns and defects concentrated at the distal end of the casting. Aiming at the defect causes of the initial schemes, Scheme D and E are optimized by adding exhaust structures, optimizing the riser feeding system and expanding the cross-sectional area of the gating system for re-simulation. The results indicate that the optimized Scheme E can effectively eliminate gas entrapment and incomplete pattern decomposition, concentrate shrinkage defects in the riser area, significantly improve the controllability of the casting solidification process, and achieve the optimal casting quality, which can meet the requirements of engineering production.