Підвищення якості виливків за допомогою застосування технологій комп’ютерного 3D моделювання процесів лиття

Abstract

В роботі було проаналізовано програмних комплекс для комп’ютерного моделювання процесів лиття: MAGMASOFT®. Розглянуто методику та принципи розробки 3D моделей деталей та виливків для насосів. Розглянуто компоненти модельної оснастки, їх принципи роботи та правила застосування. Було проведено комп’ютерне моделювання на утворення усадкової раковини в таких деталях, як корпус і кришка насосу, корпус підшипника, корпус ущільнення та колесо робоче. Отримані результати були проаналізовані та обґрунтовані. Дослідження демонструє ефективність застосування програмного комплексу MAGMASOFT®, який моделює процеси лиття металів на прикладі деталей для різних насосів, який дозволяють створити оптимальну конструкцію модельної оснастки на стадії проектування і обійтися без дорогих операцій перероблення технології і зміни оснащення безпосередньо в процесі організації виробництва деталі.

The work analyzed the software complex for computer modeling of casting processes: MAGMASOFT®. The methodology and principles of developing 3D models of parts and castings for pumps are considered. The components of the model equipment, their principles of operation and rules of application are considered. Computer simulations were performed for the formation of a shrink shell in such parts as the pump housing and cover, the bearing housing, the seal housing and the impeller. The obtained results were analyzed and substantiated. The study demonstrates the effectiveness of the application of the MAGMASOFT® software complex, which simulates metal casting processes using the example of parts for various pumps, which allows you to create an optimal design of the model equipment at the design stage and avoid expensive operations of reworking the technology and changing the equipment directly in the process of organizing the production of the part. Relevance of research. Research is important in solving a large number of problems when working in foundry production. A lot of time and money is spent on the design of new parts, and if the part could not be obtained the first time, then a lot of time and money is also spent on taking into account the shortcomings and reworking its manufacturing process, which has a bad effect on the cost price and research of such products. Therefore, software complexes with the help of virtual modeling will help to reduce time and significantly reduce costs for designing products and their manufacture with obtaining the highest possible properties, the sizes of castings as close as possible to the sizes of finished parts. The object of research is the process of using software complexes and computer 3D modeling technologies to improve the quality of castings in foundry production. The subject of the study is computer 3D modeling of various types of parts, castings and their models on a shrink shell in the MAGMASOFT® software complex. The purpose of the work is to study the features of the application of 3D computer modeling technologies for castings of pump parts, which are prepared by casting in sand-clay molds to improve their quality, accuracy, and cost-effectiveness. To achieve this goal, the following tasks were identified and set in the research. 1. Research, analysis and comparison of software complexes for modeling casting processes. 2. Studying the principles, features and technologies of computer 3D modeling of pump parts. 3. Use of 3D computer modeling technologies to obtain models of parts and castings of pump parts. 4. Computer 3D modeling of castings on a shrink shell using the MAGMASOFT® software complex. 5. Analysis and systematization of the obtained casting modeling results in the MAGMASOFT® software complex. Research methods. Research methods consist in the application of computer 3D modeling for pump parts, casting of parts on a shrink shell in the MAGMASOFT® software complex, analysis of the results obtained during modeling and their recommendations for use in optimizing the process of casting pump parts. Scientific novelty. The study demonstrates the effectiveness of the application of the MAGMASOFT® software complex, which is intended for modeling metal alloy casting processes using the example of pump parts and allows to determine the optimal design of the model equipment at the design stage and to exclude from the technological process high-cost technology improvement operations by changing the equipment directly in the process of organizing production. The scientific novelty of the obtained results: 1. Analysis of two software complexes for computer 3D modeling of casting processes: MAGMASOFT® and NovaFlow & Solid. The comparative analysis made it possible to decide on the software complex for 3D modeling - MAGMASOFT®. The main arguments for this choice are that this software complex has a more convenient, wide and flexible control for setting up simulations, as well as that MAGMASOFT® is better applied to castings that have a complex configuration. 2. The considered technique and principles of creating 3D models of parts and castings on the example of the guiding device in the SolidWorks software complex. 3. Various components of the model equipment of castings for casting in sand-clay molds are presented and analyzed, their main advantages, disadvantages and methods of their application are considered. The main components of the model equipment are open and closed wooden screeds, exothermic screeds of various shapes (cylindrical, oval, lateral, etc.), rods, false stands, refrigerators and components of the shower system. 4. With the help of the MAGMASOFT® software complex, studies were carried out on the formation of shrinkage shells for such parts as the pump housing and cover, the bearing housing, the sealing housing and the impeller. All presented parts, except for the working wheel, were modeled in the MAGMASOFT® software complex for steel 25L, and the working wheel - for steel 20X13L. 5. For all the presented parts, it was possible to create a correct and working model of the casting, which showed good results during modeling. The value of these results lies not only in the theoretical data obtained during the simulation of shrink shells, but also in practical ones, since the presented parts are components of various pumps and were manufactured according to the presented models. 6. When making castings, practical and theoretical data differ within the margin of error. The main reason for the discrepancy in the data is that the modeling takes into account ideal conditions during pouring, and in practice there are subjective factors that depend on the qualifications of the workers. Also, the amount of error is affected by the method of pouring. With manual pouring, in contrast to machine pouring, there is a discrepancy in the speed of pouring steel, which affects the formation of slag and the tendency to break the mold.