DEVELOPMENT OF A FOUNDRY TECHNOLOGY FOR OBTAINING A CAST PROTECTIVE MODULE BY LOST FOAM CASTING

Abstract

Purpose. Development of a foundry technology for obtaining a hollow casting of a protective module by lost foam casting.
 Research methods. Computer simulation of foundry processes was used and practical experiments were carried out.
 Results. Based on the analysis of metal pouring processes using computer simulation, the hydrodynamic conditions for pouring the protective module casting with different gating systems were established. With the upper distributed gating system, filling occurs from the center to the edges. At the same time, the hydrodynamic pressure of the metal causes uneven filling of the walls of the casting, as a result of which a large metal flow front is formed. With the lower one-sided downpour system, the area of the flow front decreases, and the filling of the mold occurs evenly, which eliminates the possibility of sand collapse. The results of simulation of metal solidification processes showed that there are no shrinkage holes in the casting of the module, but there is a slight microporosity due to the construction of the casting.
 Scientific novelty. It was determined that the formation of a collapse defect in a casting with the upper gating system during lost foam casting occurs due to a large front of the metal flow, which leads to excessive release of gases and the formation of low vacuum conditions in the core parts of the mold, as a result of which the impact of the jet metal occurs local sand collapse.
 Practical value. The gating system and the overall technological process of obtaining cast protective modules from steel by lost foam casting were optimized.