12/12/2020 Analysis of the numerical simulation results of the casting process of the double h…

Analysis of the numerical simulation results

of the casting process of the double
hydraulic valve body
1.Simulation results and analysis of filling process
The filling process of multi way valve casting is as shown in the figure. It can be
seen from the figure that when the liquid metal just enters the cavity, i.e. before
5.5s, the filling is not stable, resulting in splashing and the phenomenon of
multiple streams of liquid converging. However, in the later filling process, the
pouring is gradually stable, which can effectively prevent the formation of air
entrainment and slag inclusion defects. The main reason for the unsteadiness at
the beginning of pouring is that the liquid metal is introduced into the cavity from
the middle of the casting. When the liquid metal just enters the cavity, it impacts
the lower surface of the cavity, resulting in unstable filling and splashing. In
addition, the liquid metal is introduced from one end of the casting. Because the
cavity of the casting is complex and variable, and the flow resistance is large,
multiple streams of liquid metal appear when the liquid metal just enters the
cavity The pouring is not stable.

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12/12/2020 Analysis of the numerical simulation results of the casting process of the double h…

2.Simulation results and analysis of solidification process

The figure shows the cloud chart of solidification time in the casting processof
valve body. It can be seen from the figure that the casting solidifies from all sides
to the inside, and the final solidification position is the middle part of the casting,
which is near the middle position of multi way valve boom joint. The reason is
that the outer surface of the casting is in direct contact with the mold, with large
heat dissipation area and temperature gradient, the casting is easy to cool and
then solidify; the inner part of the casting is subject to the outer layer It is difficult
to cool and has a long solidification time.

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12/12/2020 Analysis of the numerical simulation results of the casting process of the double h…

The figure shows the distribution of shrinkage cavity when the porosity is greater
than 1% (macro shrinkage when the porosity is greater than 1%). It can be seen
from the figure that there are many places of shrinkage cavity in the valve body,
with the maximum porosity of 72.7%; among them, there are shrinkage cavity
near the last solidified part of the valve body, i.e. the middle oil inlet of the multi
way valve boom joint; in addition, there are shrinkage cavity near the important
oil passage of the valve body, which seriously affects the performance of the
multi way valve; in addition, there are also shrinkage cavity around the four screw
holes Shrinkage cavity.

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12/12/2020 Analysis of the numerical simulation results of the casting process of the double h…

The main reason is that the casting always solidifies from the outside to the
inside. During the solidification process, an isolated liquid-phase area will
inevitably form. With the continuous cooling, the solidified part needs to complete
the solid-phase shrinkage, while the isolated liquid-phase area needs to
complete the liquid-phase shrinkage, volume expansion and solid-phase
shrinkage. The expansion volume is not enough to make up the shrinkage of the
liquid metal, and there is no liquid to supplement the shrinkage. Therefore, in the
casting In addition, due to the complex structure of multi-channel valve body,
there are many narrow and long special-shaped holes and grooves in the
complex inner cavity valve body with high integration degree, forming hot spot,
which makes the casting shrinkage resistance larger during solidification, and
finally forming shrinkage cavity.

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