A method and system for predicting shrinkage defects of castings based on virtual simulation technology

Abstract

The application relates to the field of casting technology, in particular to a casting shrinkage hole defect prediction method and system based on virtual simulation technology.The method comprises the following steps: acquiring casting planning information, analyzing the casting planning information, and determining simulation parameters; performing simulation simulation according to the simulation parameters, obtaining a simulation result, and determining a shrinkage hole condition according to the simulation result; acquiring casting requirement information, analyzing the casting requirement information, and determining an expected flatness; adjusting the simulation parameters according to the shrinkage hole condition, and repeating the steps according to the adjusted simulation parameters until the simulation result meets the expected flatness. Possible shrinkage hole areas can be accurately identified. These areas are usually places where the temperature drops faster or where the cooling is uneven. Therefore, clear references are provided for subsequent process adjustment. According to the actual use and customer requirements of the casting, the quality standards of the casting in appearance and function are determined.

Description

Technical Field

[0001] This application relates to the field of casting technology, and in particular to a method and system for predicting shrinkage defects in castings based on virtual simulation technology. Background Technology

[0002] Virtual simulation technology can use computer simulations to predict key factors such as heat flow, stress, and deformation during the casting process, thereby identifying potential defects in advance, optimizing the casting process, and reducing experimental costs and trial-and-error processes in production. Shrinkage cavities are a common defect in casting, referring to voids formed inside or on the surface of the casting due to uneven cooling or poor metal flow. Shrinkage cavities not only affect the appearance quality of the casting but also severely reduce its mechanical properties, and can even lead to casting failure.

[0003] While existing simulation methods can predict potential defects during the casting process, the key challenge for the industry remains how to effectively adjust simulation parameters based on these results to optimize the casting process, improve the overall level of casting manufacturing, and ultimately achieve the desired casting quality. Summary of the Invention

[0004] This application provides a method and system for predicting shrinkage cavities in castings based on virtual simulation technology, in order to solve the above-mentioned problems.

[0005] In a first aspect, this application provides a method for predicting shrinkage cavity defects in castings based on virtual simulation technology, the method comprising:

[0006] S1. Obtain casting planning information, analyze the casting planning information, and determine simulation parameters;

[0007] S2. Perform simulation based on the simulation parameters to obtain simulation results, and determine the shrinkage cavity situation based on the simulation results;

[0008] S3. Obtain casting requirement information, analyze the casting requirement information, and determine the desired flatness;

[0009] S4. Adjust the simulation parameters according to the shrinkage situation, and repeat step S2 according to the adjusted simulation parameters until the simulation result meets the desired flatness.

[0010] This solution determines key simulation parameters (such as casting temperature, flow rate, and cooling rate) based on the specific design of the casting (e.g., the location of gates, risers, and runners) and material properties, providing a foundation for subsequent simulation and optimization. In-depth analysis of casting planning information allows for the early detection of potential issues affecting casting quality. For example, dead zones may lead to poor metal flow, resulting in shrinkage cavities; these potential problems will be reflected in subsequent simulations. Analyzing simulation results allows for the accurate identification of possible shrinkage cavity areas. The simulation provides the probability and location of shrinkage cavities, providing a basis for further optimization. Visualizing the simulation results helps technicians more intuitively understand potential defects and temperature changes during the casting process, providing a clear reference for subsequent process adjustments. Based on the actual application of the casting and customer requirements, the quality standards for the casting's appearance and function are clearly defined. By analyzing shrinkage cavity conditions (such as excessively rapid cooling or excessively high casting speeds), the simulation parameters are precisely adjusted. For example, appropriately increasing the casting temperature, decreasing the casting speed, or optimizing the temperature field distribution by changing the cooling method can ensure that there are no excessive temperature differences inside the casting, thereby effectively preventing the formation of shrinkage cavities. Each adjusted simulation will provide new simulation results. Based on the new simulation results, technicians continue to analyze the defects in the casting, especially shrinkage cavities and surface quality, to ensure that these problems are effectively resolved.

[0011] Optionally, the analysis of the casting planning information to determine the simulation parameters includes:

[0012] Analyze the casting planning information to determine the location of the gating gate, gating system, and riser.

[0013] Obtain casting information to determine casting properties and structure;

[0014] The simulation parameters are determined based on the casting properties, casting structure, gate location, gating system location, and riser location.

[0015] This method determines the location and dimensions of the gating system, runner, and riser, information that directly affects the flow of molten metal and the cooling process of the casting. It identifies hot spots, thin walls, and stress concentration areas in the casting structure, which are prone to defects such as shrinkage cavities and cracks during casting. It determines the melting point, thermal conductivity, shrinkage rate, and other properties of the selected material, which affect the solidification process and final dimensional accuracy of the casting. A suitable pouring temperature ensures good fluidity and filling properties of the molten metal, reducing the formation of shrinkage cavities and cracks. Controlling the pouring speed prevents the molten metal from flowing too fast or too slow, thus reducing defects such as incomplete filling and cold shuts. Selecting an appropriate cooling method controls the cooling rate of the casting, reducing shrinkage cavities and deformation.

[0016] Optionally, the simulation parameters include casting temperature, and before determining the shrinkage cavity situation based on the simulation results, the method further includes:

[0017] Based on the casting structure, determine the casting partitioning;

[0018] Based on the zoning of the casting, the casting data is obtained;

[0019] Analyze the casting data to determine the temperature changes during the casting process;

[0020] Based on the temperature changes and the casting temperature, a special area is determined.

[0021] This approach breaks down complex castings into more manageable and analyzable regions. By partitioning these regions, the thermal flow and solidification behavior of each can be simulated and analyzed more accurately, providing a foundation for subsequent temperature variation analysis and the identification of special areas. Actual casting data related to each region, such as casting temperature and casting speed, is collected. This data is crucial for simulating the flow and solidification process of molten metal, contributing to improved simulation accuracy and reliability. Analysis of the casting data reveals temperature variations in the casting during the casting process. This helps identify high-risk areas for shrinkage cavities and provides a basis for identifying special areas. Special areas prone to shrinkage cavities due to temperature variations and casting temperatures are identified. These areas may require specific casting process adjustments or feeding measures to reduce defect formation.

[0022] Optionally, determining the simulation parameters based on the casting properties, casting structure, gate location, gating system location, and riser location includes:

[0023] Based on the casting structure, determine the structural changes in the special region;

[0024] Based on the structural changes, the casting dead zone is determined;

[0025] The casting speed of the casting dead angle is determined based on the gate position and the runner position.

[0026] The initial casting speed is determined based on the casting speed in the dead zone, the gate position, and the runner position.

[0027] The cooling method for the casting is determined based on the structural changes described above;

[0028] The casting temperature and casting pressure are determined based on the initial casting speed and the casting cooling method.

[0029] The casting temperature, the casting pressure, and the initial casting speed are determined as the simulation parameters.

[0030] This method identifies special regions in castings, such as hot spots, thin walls, and complex shapes, and analyzes their structural changes during the casting process. This helps predict potential casting defects in these regions, such as shrinkage cavities and cracks. Based on the design of the gate and runner, the pouring speed in dead zones is determined. An appropriate pouring speed helps ensure sufficient filling of dead zones with molten metal, reducing defects. Based on the pouring speed in dead zones and other relevant factors, the initial pouring speed for the entire casting is determined. This is crucial for ensuring uniform flow of molten metal throughout the mold. A suitable cooling method is selected based on the casting's structural changes and material properties. The choice of cooling method significantly impacts the stress and deformation of the casting. Based on the initial pouring speed and the casting cooling method, the pouring temperature and pressure are determined; these parameters directly affect the fluidity of the molten metal and the solidification process of the casting. These determined parameters are used as simulation parameters for the casting process simulation; these parameters directly affect the accuracy of the simulation and the prediction of defects.

[0031] Optionally, adjusting the simulation parameters according to the cavity shrinkage condition includes:

[0032] Based on the structural changes, the casting structure is disassembled into cell units to obtain casting units;

[0033] Based on the described shrinkage cavity situation, the defect location is determined, and the shrinkage cavity situation is analyzed to determine the shrinkage cavity size and actual temperature change at each defect location.

[0034] Based on the location of the defect, determine the associated location;

[0035] The adjustment area is determined based on the associated location and the defect location;

[0036] Based on the size of the shrinkage cavity and the actual temperature change, determine the expected temperature for resolving the shrinkage cavity at the defect location;

[0037] The simulation parameters are adjusted according to the desired temperature.

[0038] This approach breaks down complex casting structures into smaller, more manageable units. These units can be simulated independently, facilitating more accurate analysis of local casting behavior, such as hot spots and shrinkage cavities. It identifies the location of shrinkage defects in the casting and analyzes their specific characteristics. Determining the size of the shrinkage cavity and actual temperature variations provides a basis for subsequent defect resolution. It identifies other locations related to the defect location, which may influence or be influenced by the defect. Identifying these related locations helps in a comprehensive understanding of the defect's formation. Specific areas requiring adjustment are determined to address the shrinkage defect. These areas may include the defect location itself and its associated locations. Based on the size of the shrinkage cavity and actual temperature variations, a desired temperature range is determined to address the shrinkage problem. This temperature range will guide the adjustment of simulation parameters. Based on the determined desired temperature, simulation parameters, such as casting temperature, casting speed, and cooling method, are adjusted to resolve the shrinkage issue.

[0039] Optionally, adjusting the simulation parameters according to the desired temperature includes:

[0040] Determine the gate diameter based on the gate location;

[0041] Based on the gate diameter, analyze the casting structure and determine the gate adjustment position;

[0042] The casting position is determined based on the casting temperature, the initial casting speed, and the desired temperature.

[0043] Based on the casting position and the gate adjustment position, determine the gate position adjustment scheme;

[0044] The simulation parameters are adjusted according to the gate position adjustment scheme.

[0045] This scheme determines the appropriate gate diameter based on the gate's location and the casting's geometry. The gate diameter affects the flow rate and volume of the molten metal, thus influencing the filling and solidification process of the casting. The impact of the gate diameter on the casting structure is analyzed, and the locations where the gate may need adjustment are determined based on the analysis results. This helps optimize the gating system and reduce defect formation. The optimal pouring location of the molten metal is determined based on the pouring temperature, initial pouring speed, and desired temperature. This helps ensure that the molten metal fills the mold uniformly, reducing defect formation. Based on the pouring location and potential gate adjustments, an adjustment scheme for the gate location is determined. This helps optimize the gating system and improve casting quality. Based on the gate location adjustment scheme, simulation parameters, such as pouring temperature, pouring speed, and cooling method, are adjusted. This helps improve the accuracy of the simulation and the quality of the casting.

[0046] Optionally, the step of analyzing the casting structure based on the gate diameter and determining the gate adjustment position includes:

[0047] Based on the gate diameter, the casting structure is analyzed to determine a suitable location that meets the gate diameter requirement;

[0048] Analyze the surrounding structure of the suitable location to determine the polishing difficulty;

[0049] Based on the difficulty of the polishing, determine whether to use the appropriate position as the gate adjustment position.

[0050] This solution ensures that the gate location meets the gate diameter requirements while taking into account the structural characteristics of the casting, such as wall thickness, shape, and hot spots. This helps avoid uneven molten metal flow or defects caused by improper gate placement. The impact of the casting structure around the gate on the grinding process, as well as the ease of grinding, is assessed. This contributes to improved efficiency and quality in subsequent manufacturing processes. The gate location is adjusted based on the grinding difficulty to ensure casting quality and production efficiency.

[0051] Optionally, adjusting the simulation parameters according to the gate position adjustment scheme includes:

[0052] Based on the described shrinkage cavity conditions, determine the location of the cooling point;

[0053] Based on the location of the gate and the location of the cooling point, determine the riser adjustment scheme;

[0054] The simulation parameters are adjusted according to the gate position adjustment scheme and the riser adjustment scheme.

[0055] This scheme analyzes shrinkage cavities in castings to determine the location of cooling points, allowing for controlled cooling to reduce or eliminate shrinkage defects. Based on the location of the gating and cooling points, the riser design is adjusted to ensure the molten metal fully fills the mold and minimizes defects. Following the gating and riser adjustments, simulation parameters are refined to optimize casting quality.

[0056] Optionally, determining the associated location based on the defect location includes:

[0057] The actual heating condition at the defect location is determined based on the casting speed and the initial casting temperature.

[0058] Based on the desired flatness and the casting properties, determine the desired heat level to achieve the desired flatness under the influence of the casting properties;

[0059] The influence range of the defect location is determined based on the temperature change and the expected heat.

[0060] Based on the described scope of influence, determine the associated location.

[0061] This approach aims to understand the actual heating conditions at the defect location during the casting process, providing a basis for subsequent temperature control and defect prevention. It determines the desired heat the casting should reach during cooling to achieve the desired casting flatness. The temperature influence range around the defect location is determined to facilitate appropriate measures. The temperature gradient around the defect location is analyzed to identify the affected heat transfer area. Based on temperature changes and the desired heat, the influence range of the defect location is determined. Based on the influence range of the defect location, related locations are identified for overall casting optimization.

[0062] Secondly, this application provides a casting shrinkage cavity defect prediction system based on virtual simulation technology, the system comprising:

[0063] The information analysis module is used to acquire casting planning information, analyze the casting planning information, and determine simulation parameters;

[0064] The cavity reduction determination module is used to perform simulation based on the simulation parameters, obtain simulation results, and determine the cavity reduction situation based on the simulation results;

[0065] The requirements analysis module is used to obtain casting requirements information, analyze the casting requirements information, and determine the desired flatness.

[0066] The adjustment module is used to adjust the simulation parameters according to the hole shrinkage situation, and to repeatedly execute the hole shrinkage determination module according to the adjusted simulation parameters until the simulation result meets the expected flatness.

[0067] Optionally, when the information analysis module analyzes the casting planning information and determines the simulation parameters, it is used for:

[0068] Analyze the casting planning information to determine the location of the gating gate, gating system, and riser.

[0069] Obtain casting information to determine casting properties and structure;

[0070] The simulation parameters are determined based on the casting properties, casting structure, gate location, gating system location, and riser location.

[0071] Optionally, the simulation parameters include casting temperature, and the casting shrinkage cavity defect prediction system further includes a region analysis module for:

[0072] Based on the casting structure, determine the casting partitioning;

[0073] Based on the zoning of the casting, the casting data is obtained;

[0074] Analyze the casting data to determine the temperature changes during the casting process;

[0075] Based on the temperature changes and the casting temperature, a special area is determined.

[0076] Optionally, when the information analysis module determines the simulation parameters based on the casting attributes, the casting structure, the gate location, the gating system location, and the riser location, it is used for:

[0077] Based on the casting structure, determine the structural changes in the special region;

[0078] Based on the structural changes, the casting dead zone is determined;

[0079] The casting speed of the casting dead angle is determined based on the gate position and the runner position.

[0080] The initial casting speed is determined based on the casting speed in the dead zone, the gate position, and the runner position.

[0081] The cooling method for the casting is determined based on the structural changes described above;

[0082] The casting temperature and casting pressure are determined based on the initial casting speed and the casting cooling method.

[0083] The casting temperature, the casting pressure, and the initial casting speed are determined as the simulation parameters.

[0084] Optionally, when the adjustment module adjusts the simulation parameters according to the hole shrinkage situation, it is used to:

[0085] Based on the structural changes, the casting structure is disassembled into cell units to obtain casting units;

[0086] Based on the described shrinkage cavity situation, the defect location is determined, and the shrinkage cavity situation is analyzed to determine the shrinkage cavity size and actual temperature change at each defect location.

[0087] Based on the location of the defect, determine the associated location;

[0088] The adjustment area is determined based on the associated location and the defect location;

[0089] Based on the size of the shrinkage cavity and the actual temperature change, determine the expected temperature for resolving the shrinkage cavity at the defect location;

[0090] The simulation parameters are adjusted according to the desired temperature.

[0091] Optionally, when the adjustment module adjusts the simulation parameters according to the desired temperature, it is used to:

[0092] Determine the gate diameter based on the gate location;

[0093] Based on the gate diameter, analyze the casting structure and determine the gate adjustment position;

[0094] The casting position is determined based on the casting temperature, the initial casting speed, and the desired temperature.

[0095] Based on the casting position and the gate adjustment position, determine the gate position adjustment scheme;

[0096] The simulation parameters are adjusted according to the gate position adjustment scheme.

[0097] Optionally, when the adjustment module analyzes the casting structure based on the gate diameter to determine the gate adjustment position, it is used for:

[0098] Based on the gate diameter, the casting structure is analyzed to determine a suitable location that meets the gate diameter requirement;

[0099] Analyze the surrounding structure of the suitable location to determine the polishing difficulty;

[0100] Based on the difficulty of the polishing, determine whether to use the appropriate position as the gate adjustment position.

[0101] Optionally, when the adjustment module adjusts the simulation parameters according to the gate position adjustment scheme, it is used to:

[0102] Based on the described shrinkage cavity conditions, determine the location of the cooling point;

[0103] Based on the location of the gate and the location of the cooling point, determine the riser adjustment scheme;

[0104] The simulation parameters are adjusted according to the gate position adjustment scheme and the riser adjustment scheme.

[0105] Optionally, when the adjustment module determines the associated location based on the defect location, it is used to:

[0106] The actual heating condition at the defect location is determined based on the casting speed and the initial casting temperature.

[0107] Based on the desired flatness and the casting properties, determine the desired heat level to achieve the desired flatness under the influence of the casting properties;

[0108] The influence range of the defect location is determined based on the temperature change and the expected heat.

[0109] Based on the described scope of influence, determine the associated location. Attached Figure Description

[0110] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0111] Figure 1 This is a schematic diagram of an application scenario provided in an embodiment of this application;

[0112] Figure 2 A flowchart illustrating a method for predicting shrinkage cavities in castings based on virtual simulation technology, provided in an embodiment of this application;

[0113] Figure 3 This is a schematic diagram of a casting shrinkage cavity defect prediction system based on virtual simulation technology, provided as an embodiment of this application. Detailed Implementation

[0114] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application.

[0115] Furthermore, the term "and / or" in this article is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, or B existing alone. Additionally, the character " / " in this article, unless otherwise specified, generally indicates that the preceding and following related objects have an "or" relationship.

[0116] The embodiments of this application will now be described in further detail with reference to the accompanying drawings.

[0117] Virtual simulation technology can use computer simulations to predict key factors such as heat flow, stress, and deformation during the casting process, thereby identifying potential defects in advance, optimizing the casting process, and reducing experimental costs and trial-and-error processes in production. Shrinkage cavities are a common defect in casting, referring to voids formed inside or on the surface of the casting due to uneven cooling or poor metal flow. Shrinkage cavities not only affect the appearance quality of the casting but also severely reduce its mechanical properties, and can even lead to casting failure.

[0118] While existing simulation methods can predict defects, how to effectively adjust simulation parameters based on simulation results to optimize the casting process, thereby effectively reducing or eliminating shrinkage defects and achieving the desired casting quality, remains an urgent problem to be solved.

[0119] Based on this, this application provides a method and system for predicting shrinkage cavity defects in castings based on virtual simulation technology. The method comprises: S1. Obtaining and analyzing casting planning information to determine simulation parameters; S2. Performing simulation based on the simulation parameters to obtain simulation results and determining the shrinkage cavity situation based on the simulation results; S3. Obtaining and analyzing casting requirement information to determine the desired flatness; S4. Adjusting the simulation parameters according to the shrinkage cavity situation, and repeating step S2 based on the adjusted simulation parameters until the simulation results meet the desired flatness. Based on the specific design of the casting (such as the location of the gate, riser, and runner) and material properties, key simulation parameters (such as casting temperature, flow rate, and cooling rate) are determined, providing a foundation for subsequent simulation and optimization. These parameters directly determine the reliability of the simulation results. In-depth analysis of the casting planning information can identify potential problems affecting casting quality in advance. For example, dead corners may lead to poor metal flow, thus causing shrinkage cavities; these potential problems will be reflected in subsequent simulations. By analyzing the simulation results, possible shrinkage cavity areas can be accurately identified. These areas typically manifest as locations where temperatures drop rapidly or where cooling is uneven. Simulations can provide the probability and location of shrinkage cavities, providing a basis for further optimization. Visualizing simulation results helps technicians more intuitively understand potential defects and temperature changes during the casting process, thus providing a clear reference for subsequent process adjustments. Obtaining and analyzing casting requirement information is crucial for determining the desired flatness. Desired flatness typically involves the smoothness, shape, and dimensional accuracy of the casting surface. Based on the actual application of the casting and customer requirements, the quality standards for the casting's appearance and function are clearly defined. By analyzing shrinkage cavity conditions (such as excessively rapid cooling or excessively high casting speeds), simulation parameters are precisely adjusted. For example, appropriately increasing the casting temperature, decreasing the casting speed, or optimizing the temperature field distribution by changing the cooling method ensures that there are no excessive temperature differences inside the casting, thereby effectively preventing the formation of shrinkage cavities. Each adjusted simulation provides new simulation results. Technicians continue to analyze casting defects based on the new simulation results, especially shrinkage cavities and surface quality, ensuring that these problems are effectively resolved.

[0120] Figure 1This application provides an schematic diagram of an application scenario, illustrating the use of the method provided in this application during casting simulation. Specifically, the method is applied to any server, which interacts with the design database to obtain casting planning information and simulation parameters. Based on the specific design of the casting (such as the location of gates, risers, and runners) and material properties, key simulation parameters (such as casting temperature, flow rate, and cooling rate) are determined, providing a foundation for subsequent simulation and optimization. These parameters directly determine the reliability of the simulation results. In-depth analysis of the casting planning information can identify potential problems affecting casting quality in advance. Analysis of simulation results can accurately identify potential shrinkage cavity areas. These areas typically manifest as locations where the temperature drops rapidly or where cooling is uneven. Simulation can provide the probability and location of shrinkage cavities, providing a basis for further optimization. Visualization of simulation results helps technicians more intuitively understand potential defects and temperature changes during the casting process, thus providing a clear reference for subsequent process adjustments. Desired flatness typically involves the smoothness, shape, and dimensional accuracy of the casting surface. Based on the actual application of the casting and customer requirements, the quality standards for the casting's appearance and function are clearly defined. By analyzing shrinkage cavities (such as those caused by excessively rapid cooling or excessively high casting speed), simulation parameters are precisely adjusted to effectively prevent the formation of shrinkage cavities. Each adjusted simulation provides new results. Technicians then use these new simulation results to further analyze casting defects, particularly shrinkage cavities and surface quality, ensuring these issues are effectively resolved.

[0121] By precisely controlling simulation parameters and optimizing temperature distribution and metal flow, shrinkage cavities in castings can be significantly reduced, improving their internal quality. The desired flatness target can ultimately be met, resulting in smoother, defect-free casting surfaces that satisfy customer and usage requirements. Through continuous iteration and optimization, the precision of the casting process is improved, reducing experimentation and trial-and-error processes, lowering production costs, and simultaneously enhancing the consistency and reliability of castings. Specific implementation methods can be found in the following examples.

[0122] Figure 2 This is a flowchart illustrating a method for predicting shrinkage cavities in castings based on virtual simulation technology, provided as an embodiment of this application. The method of this embodiment can be applied to servers in the above scenarios. Figure 2 As shown, the method includes:

[0123] S1. Obtain casting planning information, analyze the casting planning information, and determine simulation parameters.

[0124] Retrieve casting planning information from the design database. This information can be from the casting design stage, which involves planning the casting production process based on product design requirements, material properties, production equipment, and process conditions.

[0125] Simulation parameters can be variables used to control simulation behavior during the simulation process, such as casting temperature, casting speed, cooling rate, material properties, boundary conditions, etc.

[0126] Specifically, the first step is to obtain the geometric information, material properties, and dimensional data of the casting from the CAD model or casting design. This is especially important for the location and dimensions of crucial casting channels such as gates, runners, and risers. Based on the casting's geometry, the system analyzes whether it contains complex structural features, such as dead angles or thin-walled sections. These features may impede metal flow, leading to shrinkage cavities. By analyzing the casting planning information and considering the casting's material properties, key simulation parameters such as casting temperature, flow rate, and cooling method are determined. These parameters play a crucial role in the simulation results.

[0127] S2. Perform simulation based on the simulation parameters, obtain simulation results, and determine the shrinkage cavity situation based on the simulation results;

[0128] Simulation can be the use of computer software to simulate a real or hypothetical system in order to predict the system’s behavior under different conditions.

[0129] Simulation results can be the data output after the simulation is completed, reflecting the behavior and state of the system during the simulation process. Simulation results can include temperature field, flow field, solidification process, stress distribution, etc.

[0130] Shrinkage cavities can be voids formed inside or on the surface of a casting, usually due to the shrinkage of molten metal during cooling.

[0131] Specifically, simulation parameters are obtained from the design database, and then virtual simulation is performed based on these parameters. The simulation accurately simulates phenomena such as heat flow, flow rate, and temperature changes during the casting process, and the occurrence of shrinkage cavities is determined through analysis of the results. Professional casting simulation software (such as ProCAST, FLOW-3D, etc.) is used to simulate the casting process. By inputting the simulation parameters determined in the first step, such as casting temperature, flow rate, and cooling method, a thermo-fluid-mechanical coupled simulation of the casting is performed. The simulation results are used to examine the temperature distribution, flow state, and solidification process of the casting. In the simulation, the potential locations of shrinkage cavities are determined by judging whether the internal temperature gradient and metal flow are uniform. Regions with excessively large temperature gradients are identified in the simulation results; these regions are often high-risk areas for shrinkage cavities. By predicting the location and size of shrinkage cavities, key areas requiring optimization are identified.

[0132] S3. Obtain casting requirement information, analyze the casting requirement information, and determine the desired flatness;

[0133] Casting requirements information can be the performance and appearance requirements that the casting needs to meet in the final application, such as mechanical properties, dimensional accuracy, appearance requirements, and operating environment.

[0134] Desired flatness refers to the degree of flatness that the surface of a casting is expected to achieve, and it is usually related to the intended use and appearance requirements of the casting.

[0135] Specifically, in the simulation process, in addition to considering shrinkage cavity issues, it is also necessary to determine the desired casting quality based on the actual application requirements of the casting (such as strength, appearance, and flatness). Desired flatness typically refers to the smoothness of the casting surface and the accuracy of its shape. Especially in castings requiring high surface quality, shrinkage cavity and deformation must be minimized. The standard for desired flatness is determined based on the casting's requirements. For example, the casting surface must achieve a certain level of smoothness or deformation accuracy. By analyzing the casting flatness and combining it with the areas that may cause deformation in the simulation results, the optimization target for flatness is determined.

[0136] S4. Adjust the simulation parameters according to the shrinkage situation, and repeat step S2 according to the adjusted simulation parameters until the simulation result meets the desired flatness.

[0137] Specifically, the simulation results predict shrinkage cavities, and the simulation parameters are dynamically adjusted based on the desired casting quality standards (such as flatness) until satisfactory simulation results are obtained. Based on the shrinkage cavities determined by the simulation results, the causes of the defects are identified and analyzed, such as excessively rapid cooling or excessively high casting speeds. These parameters are then adjusted specifically to optimize the casting temperature control and metal flow path. The simulation is repeated by adjusting the simulation parameters (such as increasing the casting temperature, changing the cooling method, or optimizing the gate position). After each simulation, the results are analyzed to see if shrinkage cavities have been reduced and flatness improved. After adjusting the simulation parameters, the flatness and surface quality of the casting are checked to verify whether they meet the standards required in the casting specifications. If the simulation results still do not achieve the desired flatness, the parameters need to be adjusted again and the simulation process repeated.

[0138] This solution determines key simulation parameters (such as casting temperature, flow rate, and cooling rate) based on the specific design of the casting (e.g., the location of gates, risers, and runners) and material properties, providing a foundation for subsequent simulation and optimization. In-depth analysis of casting planning information allows for the early detection of potential issues affecting casting quality. For example, dead zones may lead to poor metal flow, resulting in shrinkage cavities; these potential problems will be reflected in subsequent simulations. Analyzing simulation results allows for the accurate identification of possible shrinkage cavity areas. The simulation provides the probability and location of shrinkage cavities, providing a basis for further optimization. Visualizing the simulation results helps technicians more intuitively understand potential defects and temperature changes during the casting process, providing a clear reference for subsequent process adjustments. Based on the actual application of the casting and customer requirements, the quality standards for the casting's appearance and function are clearly defined. By analyzing shrinkage cavity conditions (such as excessively rapid cooling or excessively high casting speeds), the simulation parameters are precisely adjusted. For example, appropriately increasing the casting temperature, decreasing the casting speed, or optimizing the temperature field distribution by changing the cooling method can ensure that there are no excessive temperature differences inside the casting, thereby effectively preventing the formation of shrinkage cavities. Each adjusted simulation will provide new simulation results. Based on the new simulation results, technicians continue to analyze the defects in the casting, especially shrinkage cavities and surface quality, to ensure that these problems are effectively resolved.

[0139] In some embodiments, casting planning information is analyzed to determine the gate location, gating location, and riser location; casting information is obtained to determine the casting attributes and casting structure; and simulation parameters are determined based on the casting attributes, casting structure, gate location, gating location, and riser location.

[0140] Casting information can include all data related to casting production, such as geometry, material, quality requirements, performance requirements, surface quality, machining requirements, inspection standards, etc.

[0141] Casting properties can be the characteristics exhibited by castings under specific conditions. These characteristics are usually determined by the casting's material, structure, and manufacturing process, such as physical properties: density, melting point, coefficient of thermal expansion, thermal conductivity, etc.; mechanical properties: strength, hardness, toughness, fatigue strength, etc.; chemical properties: corrosion resistance, oxidation resistance, chemical stability, etc.; and heat treatment properties: weldability, heat treatability, castability, etc.

[0142] The structure of a casting can be its geometry, internal structure, and the relationships between its various parts. Geometric features include wall thickness, shape, and dimensions; internal structure includes internal holes, ribs, and supports; connection methods include welding and riveting; stress distribution includes the stress distribution that may occur during casting and use; and cooling methods include the cooling rate and method of cooling the casting, such as water cooling and air cooling.

[0143] Specifically, review the casting design drawings, including dimensions, shape, wall thickness, and connection points. Determine the location and dimensions of the gating gate, runner, and riser, as these are critical channels for molten metal flow. Select appropriate casting materials, such as cast iron, cast steel, or aluminum alloys, based on the casting's functional and performance requirements. Analyze the casting's geometry and structural characteristics to identify potential stress concentration areas and hot spots. Analyze the physical and chemical properties of the selected materials, such as melting point, thermal conductivity, and shrinkage rate. Optimize the gating system design based on the casting's geometry and structural characteristics to ensure uniform molten metal flow and filling efficiency. Determine a suitable pouring temperature based on material properties and the gating system design to ensure molten metal fluidity and filling efficiency. Determine a suitable pouring speed based on the gating system design and the casting's structural characteristics to avoid defects caused by excessively fast or slow molten metal flow. Select an appropriate cooling method, such as water cooling or air cooling, based on the casting's structure and material properties to control the cooling rate and shrinkage of the casting.

[0144] This method determines the location and dimensions of the gating system, runner, and riser, information that directly affects the flow of molten metal and the cooling process of the casting. It identifies hot spots, thin walls, and stress concentration areas in the casting structure, which are prone to defects such as shrinkage cavities and cracks during casting. It determines the melting point, thermal conductivity, shrinkage rate, and other properties of the selected material, which affect the solidification process and final dimensional accuracy of the casting. A suitable pouring temperature ensures good fluidity and filling properties of the molten metal, reducing the formation of shrinkage cavities and cracks. Controlling the pouring speed prevents the molten metal from flowing too fast or too slow, thus reducing defects such as incomplete filling and cold shuts. Selecting an appropriate cooling method controls the cooling rate of the casting, reducing shrinkage cavities and deformation.

[0145] In some embodiments, the casting zoning is determined based on the casting structure; casting data is obtained based on the casting zoning; the casting data is analyzed to determine the temperature changes during the casting process; and special areas are determined based on the temperature changes and the casting temperature.

[0146] The process of dividing a casting into different regions for simulation and analysis can be based on the casting's geometry, structural features, and casting process requirements.

[0147] Casting data can be relevant parameters and data collected during the casting process, which are used to simulate and analyze the casting process.

[0148] Temperature change can refer to the change in temperature of the casting and molten metal over time during the casting process.

[0149] Special areas are those that require special attention during the casting process, as these areas may be high-risk areas for defect formation, such as hot spots, thin walls, complex shapes, and areas near the gate.

[0150] Specifically, CAD software or casting simulation software is used to analyze the geometry of the casting, identifying areas with uneven wall thickness, complex shapes, or obvious hot spots. Key structural features in the casting, such as supports, stiffeners, and pores, are determined, as these features significantly affect the flow and cooling of the molten metal. Based on the geometry and structural features of the casting, it is divided into several regions, each with similar thermal and flow characteristics. According to the zoning, the gating system is designed, including the location and dimensions of the gate, runner, and riser. Basic parameters during the casting process are determined, such as casting temperature, casting speed, and casting time. Actual casting data, such as the temperature, flow rate, and flow volume of the molten metal, are collected during casting experiments or production. Using casting simulation software, the temperature field during the casting process is simulated based on the casting data and the zoning of the casting. The temperature gradient in the simulation results is analyzed to identify areas with drastic temperature changes, which may be high-risk areas for shrinkage cavities. The cooling rate of the casting in different regions is evaluated to identify areas that may lead to uneven cooling. Based on temperature variations and casting temperature, specific areas that may lead to shrinkage cavities, such as hot spots and thin-walled regions, are identified. A risk assessment is then conducted on these identified areas to determine which regions are most likely to develop shrinkage cavities. Optimization measures are proposed for these specific areas, such as adjusting the gating system design and modifying casting parameters.

[0151] This approach breaks down complex castings into more manageable and analyzable regions. By partitioning these regions, the thermal flow and solidification behavior of each can be simulated and analyzed more accurately, providing a foundation for subsequent temperature variation analysis and the identification of special areas. Actual casting data related to each region, such as casting temperature and casting speed, is collected. This data is crucial for simulating the flow and solidification process of molten metal, contributing to improved simulation accuracy and reliability. Analysis of the casting data reveals temperature variations in the casting during the casting process. This helps identify high-risk areas for shrinkage cavities and provides a basis for identifying special areas. Special areas prone to shrinkage cavities due to temperature variations and casting temperatures are identified. These areas may require specific casting process adjustments or feeding measures to reduce defect formation.

[0152] In some embodiments, based on the casting structure, structural changes in special areas are determined; based on the structural changes, casting dead zones are determined; based on the gate location and runner location, the casting speed in the casting dead zones is determined; based on the casting speed in the dead zones, the gate location, and the runner location, the initial casting speed is determined; based on the structural changes, the casting cooling method is determined; based on the initial casting speed and the casting cooling method, the casting temperature and casting pressure are determined; and the casting temperature, casting pressure, and initial casting speed are determined as simulation parameters.

[0153] Structural changes can be alterations in the internal or external morphology of a casting that occur during the casting process due to the flow, cooling, and solidification of molten metal.

[0154] Dead zones in casting can be areas that molten metal cannot reach or fill during the casting process due to obstructed or slow flow.

[0155] Dead-angle casting speed refers to the flow rate of molten metal that needs to be adjusted to a specific value during the casting process in order to fill the dead-angle areas.

[0156] The initial casting speed can be the initial flow rate of the molten metal at the start of casting.

[0157] The casting cooling method can be a method used after casting to cool the casting to room temperature.

[0158] Specifically, CAD software is used to analyze the geometric features of the casting, identifying areas with uneven wall thickness, complex shapes, or obvious hot spots. Potential structural changes during the casting process, such as deformation and shrinkage, are determined. Based on these structural changes, the casting is divided into special regions, such as hot spots, thin walls, and complex shapes. Areas where the molten metal is difficult to reach or flows slowly during casting are identified. Casting simulation software is used to analyze the flow path of the molten metal, identifying potential casting dead zones. The location and extent of these dead zones are confirmed through simulation results and actual production experience. The layout of the gating system and runners is designed based on the casting structure and the location of the dead zones. The casting speed in the dead zone areas is calculated based on the dimensions of the gating system and the fluidity of the molten metal. The initial casting speed is ensured to meet the requirements of the gating system design while avoiding defects in the dead zones. The initial casting speed is adjusted based on simulation results and practical experience to optimize the flow of the molten metal. A suitable cooling method is selected based on the structural changes and material properties of the casting. The temperature, flow rate, and other parameters of the cooling medium, as well as the control strategies during the cooling process, are determined. Based on the properties of the metal material, casting speed, and cooling method, the casting temperature and pressure are calculated. Through simulation and experimentation, the casting temperature and pressure are optimized to reduce defect formation. Based on the above analysis and optimization results, the final simulation parameters, including casting temperature, casting pressure, and initial casting speed, are determined.

[0159] This method identifies special regions in castings, such as hot spots, thin walls, and complex shapes, and analyzes their structural changes during the casting process. This helps predict potential casting defects in these regions, such as shrinkage cavities and cracks. Based on the design of the gate and runner, the pouring speed in dead zones is determined. An appropriate pouring speed helps ensure sufficient filling of dead zones with molten metal, reducing defects. Based on the pouring speed in dead zones and other relevant factors, the initial pouring speed for the entire casting is determined. This is crucial for ensuring uniform flow of molten metal throughout the mold. A suitable cooling method is selected based on the casting's structural changes and material properties. The choice of cooling method significantly impacts the stress and deformation of the casting. Based on the initial pouring speed and the casting cooling method, the pouring temperature and pressure are determined; these parameters directly affect the fluidity of the molten metal and the solidification process of the casting. These determined parameters are used as simulation parameters for the casting process simulation; these parameters directly affect the accuracy of the simulation and the prediction of defects.

[0160] In some embodiments, the casting structure is disassembled into cell-level simulations based on structural changes to obtain casting units; the location of defects is determined based on shrinkage cavities, and the shrinkage cavities are analyzed to determine the size of the shrinkage cavity and the actual temperature change at each defect location; the associated locations are determined based on the defect locations; the adjustment area is determined based on the associated locations and the defect locations; the expected temperature for resolving shrinkage cavities at the defect locations is determined based on the size of the shrinkage cavity and the actual temperature change; and the simulation parameters are adjusted based on the expected temperature.

[0161] Cellular simulation decomposition can be a method to break down complex casting structures into smaller, more easily analyzed parts.

[0162] Casting units can be small casting parts obtained during the cell simulation disassembly process.

[0163] The defect location can be the part of the casting where the defect is located.

[0164] The size of a shrinkage cavity can be either its volume or its diameter.

[0165] Actual temperature change can refer to the temperature change of the casting during the casting process.

[0166] The associated location can be any other location that is directly related to the defect location.

[0167] The adjustment area can be the area where parameters need to be adjusted to resolve defect issues.

[0168] Specifically, simulation software is used to divide the casting into multiple cells, each representing a small area of ​​the casting. Each cell is simulated independently, and its thermal flow and solidification behavior are analyzed. Shrinkage cavities in the casting are identified through simulation results or actual inspection methods. The location, size, and surrounding temperature distribution of each shrinkage cavity are analyzed. Thermal flow and stress distribution around the defect location are analyzed to determine potential influencing factors affecting defect formation. Considering both the defect location and influencing factors, specific areas requiring adjustment are identified. Based on the size of the shrinkage cavity and actual temperature variations, a desired temperature range is set to address the shrinkage problem. Simulation parameters are adjusted according to the desired temperature, such as increasing or decreasing the casting temperature, changing the casting speed, and adjusting the cooling method.

[0169] This approach breaks down complex casting structures into smaller, more manageable units. These units can be simulated independently, facilitating more accurate analysis of local casting behavior, such as hot spots and shrinkage cavities. It identifies the location of shrinkage defects in the casting and analyzes their specific characteristics. Determining the size of the shrinkage cavity and actual temperature variations provides a basis for subsequent defect resolution. It identifies other locations related to the defect location, which may influence or be influenced by the defect. Identifying these related locations helps in a comprehensive understanding of the defect's formation. Specific areas requiring adjustment are determined to address the shrinkage defect. These areas may include the defect location itself and its associated locations. Based on the size of the shrinkage cavity and actual temperature variations, a desired temperature range is determined to address the shrinkage problem. This temperature range will guide the adjustment of simulation parameters. Based on the determined desired temperature, simulation parameters, such as casting temperature, casting speed, and cooling method, are adjusted to resolve the shrinkage issue.

[0170] In some embodiments, the gate diameter is determined based on the gate location; the casting structure is analyzed based on the gate diameter to determine the gate adjustment position; the casting position is determined based on the casting temperature, initial casting speed, and desired temperature; the gate position adjustment scheme is determined based on the casting position and the gate adjustment position; and the simulation parameters are adjusted based on the gate position adjustment scheme.

[0171] The gate diameter can be the size of the gate (the channel used to introduce molten metal into the mold).

[0172] The gate adjustment position can be determined within the casting structure, based on the gate's location and the casting's geometry, to identify the possible adjustments needed.

[0173] The casting location can be the position where the molten metal enters the mold during the casting process.

[0174] A gate position adjustment scheme is a scheme to adjust the gate position during the casting process in order to optimize the flow path of molten metal and reduce the formation of defects.

[0175] Specifically, the influence of the gating nozzle diameter on the flow of molten metal is analyzed to determine a suitable gating nozzle diameter, ensuring that the molten metal can uniformly fill the mold. Casting simulation software is used to simulate the flow path of the molten metal in the mold, analyzing the impact of the gating nozzle diameter on the flow. Based on the analysis results, the size and shape of the gating nozzle diameter are determined. The influence of the gating nozzle diameter on the casting structure is analyzed to determine the possible locations where the gating may need adjustment. Based on the analysis results, the possible locations where the gating may need adjustment are determined. The casting process is simulated using casting simulation software, analyzing the influence of casting temperature, initial casting speed, and desired temperature on the flow and solidification of the molten metal, analyzing the optimal casting position. Based on the simulation results, the optimal casting position is determined to ensure that the molten metal can uniformly fill the mold. The influence of the casting position and the gating adjustment position on the flow and solidification of the molten metal is analyzed, analyzing the adjustment schemes for the gating position, determining the optimal gating position adjustment scheme, including moving the gating position and adjusting its size. Based on the gating position adjustment scheme, the simulation parameter adjustment scheme is analyzed. Based on the analysis results, the simulation parameter adjustment scheme is determined.

[0176] This scheme determines the appropriate gate diameter based on the gate's location and the casting's geometry. The gate diameter affects the flow rate and volume of the molten metal, thus influencing the filling and solidification process of the casting. The impact of the gate diameter on the casting structure is analyzed, and the locations where the gate may need adjustment are determined based on the analysis results. This helps optimize the gating system and reduce defect formation. The optimal pouring location of the molten metal is determined based on the pouring temperature, initial pouring speed, and desired temperature. This helps ensure that the molten metal fills the mold uniformly, reducing defect formation. Based on the pouring location and potential gate adjustments, an adjustment scheme for the gate location is determined. This helps optimize the gating system and improve casting quality. Based on the gate location adjustment scheme, simulation parameters, such as pouring temperature, pouring speed, and cooling method, are adjusted. This helps improve the accuracy of the simulation and the quality of the casting.

[0177] In some embodiments, based on the gate diameter, the casting structure is analyzed to determine a suitable location that meets the gate diameter size; the surrounding structure of the suitable location is analyzed to determine the grinding difficulty; and based on the grinding difficulty, it is determined whether to use the suitable location as the gate adjustment location.

[0178] A suitable location can be determined within the casting structure, based on the gate diameter and the casting design requirements, at a location appropriate for placing the gate.

[0179] The surrounding structure can be a casting structure around a suitable location, including wall thickness, shape, stiffeners, hot spots, etc.

[0180] The difficulty of polishing can be the degree of difficulty in polishing a casting, which depends on the surrounding structure of the casting and the polishing tools used.

[0181] Specifically, casting simulation software is used to simulate the flow path of molten metal in the mold, analyzing the impact of the gating diameter on the flow. Based on the casting's structure and dimensions, a suitable gating diameter is selected to ensure the stability and efficiency of the molten metal flow. Considering the casting's structural characteristics, such as wall thickness, shape, and hot spots, it is determined whether the gating position needs adjustment. Based on the casting's structure and dimensions, a suitable gating location is selected to ensure the molten metal can uniformly fill the mold. The surrounding structure of the suitable location is analyzed, including wall thickness, shape, and hot spots, to determine whether the gating position needs adjustment. Based on the surrounding structure of the suitable location, the grinding difficulty is assessed to determine whether the gating position needs adjustment. Based on the assessment results, it is determined whether the suitable location should be used as the gating adjustment location.

[0182] This solution ensures that the gate location meets the gate diameter requirements while taking into account the structural characteristics of the casting, such as wall thickness, shape, and hot spots. This helps avoid uneven molten metal flow or defects caused by improper gate placement. The impact of the casting structure around the gate on the grinding process, as well as the ease of grinding, is assessed. This contributes to improved efficiency and quality in subsequent manufacturing processes. The gate location is adjusted based on the grinding difficulty to ensure casting quality and production efficiency.

[0183] In some embodiments, the location of the cooling point is determined based on the shrinkage cavity; the riser adjustment scheme is determined based on the gate location and the cooling point location; and the simulation parameters are adjusted based on the gate location adjustment scheme and the riser adjustment scheme.

[0184] The cooling point location can be the specific location in the casting where the molten metal is finally cooled.

[0185] Riser adjustment schemes can be designed to optimize the filling and solidification process of castings, such as increasing the number of risers, changing the riser shape, or adjusting the riser position.

[0186] Specifically, casting simulation software, such as ProCAST or MAGMA, is used to perform simulation analysis and identify shrinkage cavity locations. Based on the shrinkage cavity locations, cooling points are set to pinpoint the exact location of the shrinkage cavity in the casting due to the cooling of the molten metal at those points. The size and shape of the riser, as well as its connection method, are designed considering the locations of the gate and cooling points. The impact of the riser adjustment scheme on casting quality and production costs is evaluated. Based on the riser adjustment scheme, parameters such as casting temperature, casting speed, and cooling method are adjusted.

[0187] This scheme analyzes shrinkage cavities in castings to determine the location of cooling points, allowing for controlled cooling to reduce or eliminate shrinkage defects. Based on the location of the gating and cooling points, the riser design is adjusted to ensure the molten metal fully fills the mold and minimizes defects. Following the gating and riser adjustments, simulation parameters are refined to optimize casting quality.

[0188] In some embodiments, the actual heating conditions at the defect location are determined based on the casting speed and initial casting temperature; the expected heat to achieve the desired flatness under the influence of casting properties is determined based on the desired flatness and casting properties; the influence range of the defect location is determined based on the temperature change and the expected heat; and the associated location is determined based on the influence range.

[0189] The actual heating conditions can be the real temperature changes and heat distribution experienced by the casting during the casting process.

[0190] Desired heat can be the desired internal temperature of a casting in order to achieve specific casting quality standards, such as flatness and strength.

[0191] The range of influence can be the thermal influence range of the defect location in the casting on the surrounding area.

[0192] Specifically, casting simulation software, such as ProCAST or MAGMA, is used to simulate the casting process and analyze the actual heating conditions at the defect location. Heat flow simulation is used to understand the flow of molten metal and heat transfer within the mold. The flatness requirements of the casting are analyzed to determine the temperature conditions necessary to achieve the desired flatness. The influence of casting material, wall thickness, shape, and other properties on temperature distribution is considered. The heat transfer zone around the defect location is determined by analyzing the temperature gradient. Based on temperature changes and desired heat, the influence range of the defect location is determined, providing a basis for subsequent optimization. Analysis of the influence range identifies the casting areas directly related to the defect location.

[0193] This approach aims to understand the actual heating conditions at the defect location during the casting process, providing a basis for subsequent temperature control and defect prevention. It determines the desired heat the casting should reach during cooling to achieve the desired casting flatness. The temperature influence range around the defect location is determined to facilitate appropriate measures. The temperature gradient around the defect location is analyzed to identify the affected heat transfer area. Based on temperature changes and the desired heat, the influence range of the defect location is determined. Based on the influence range of the defect location, related locations are identified for overall casting optimization.

[0194] Figure 3 A schematic diagram of a casting shrinkage cavity defect prediction system based on virtual simulation technology is provided in one embodiment of this application, as shown below. Figure 3As shown, the casting shrinkage cavity defect prediction system 300 based on virtual simulation technology in this embodiment includes: an information analysis module 301, a shrinkage cavity determination module 302, a demand analysis module 303, and an adjustment module 304.

[0195] Information analysis module 301 is used to acquire casting planning information, analyze the casting planning information, and determine simulation parameters;

[0196] The cavity reduction determination module 302 is used to perform simulation based on the simulation parameters, obtain simulation results, and determine the cavity reduction situation based on the simulation results;

[0197] Demand analysis module 303 is used to acquire casting demand information, analyze the casting demand information, and determine the desired flatness.

[0198] The adjustment module 304 is used to adjust the simulation parameters according to the hole shrinkage situation, and to repeatedly execute the hole shrinkage determination module according to the adjusted simulation parameters until the simulation result meets the expected flatness.

[0199] Optionally, when the information analysis module 301 analyzes the casting planning information and determines the simulation parameters, it is used for:

[0200] Analyze the casting planning information to determine the location of the gating gate, gating system, and riser.

[0201] Obtain casting information to determine casting properties and structure;

[0202] The simulation parameters are determined based on the casting properties, casting structure, gate location, gating system location, and riser location.

[0203] Optionally, the simulation parameters include casting temperature, and the casting shrinkage cavity defect prediction system 300 further includes a region analysis module 305, used for:

[0204] Based on the casting structure, determine the casting partitioning;

[0205] Based on the zoning of the casting, the casting data is obtained;

[0206] Analyze the casting data to determine the temperature changes during the casting process;

[0207] Based on the temperature changes and the casting temperature, a special area is determined.

[0208] Optionally, when the information analysis module 301 determines the simulation parameters based on the casting attributes, the casting structure, the gate position, the gating position, and the riser position, it is used for:

[0209] Based on the casting structure, determine the structural changes in the special region;

[0210] Based on the structural changes, the casting dead zone is determined;

[0211] The casting speed of the casting dead angle is determined based on the gate position and the runner position.

[0212] The initial casting speed is determined based on the casting speed in the dead zone, the gate position, and the runner position.

[0213] The cooling method for the casting is determined based on the structural changes described above;

[0214] The casting temperature and casting pressure are determined based on the initial casting speed and the casting cooling method.

[0215] The casting temperature, the casting pressure, and the initial casting speed are determined as the simulation parameters.

[0216] Optionally, when the adjustment module 304 adjusts the simulation parameters according to the hole shrinkage situation, it is used to:

[0217] Based on the structural changes, the casting structure is disassembled into cell units to obtain casting units;

[0218] Based on the described shrinkage cavity situation, the defect location is determined, and the shrinkage cavity situation is analyzed to determine the shrinkage cavity size and actual temperature change at each defect location.

[0219] Based on the location of the defect, determine the associated location;

[0220] The adjustment area is determined based on the associated location and the defect location;

[0221] Based on the size of the shrinkage cavity and the actual temperature change, determine the expected temperature for resolving the shrinkage cavity at the defect location;

[0222] The simulation parameters are adjusted according to the desired temperature.

[0223] Optionally, when the adjustment module 304 adjusts the simulation parameters according to the desired temperature, it is used to:

[0224] Determine the gate diameter based on the gate location;

[0225] Based on the gate diameter, analyze the casting structure and determine the gate adjustment position;

[0226] The casting position is determined based on the casting temperature, the initial casting speed, and the desired temperature.

[0227] Based on the casting position and the gate adjustment position, determine the gate position adjustment scheme;

[0228] The simulation parameters are adjusted according to the gate position adjustment scheme.

[0229] Optionally, when the adjustment module 304 analyzes the casting structure based on the gate diameter to determine the gate adjustment position, it is used for:

[0230] Based on the gate diameter, the casting structure is analyzed to determine a suitable location that meets the gate diameter requirement;

[0231] Analyze the surrounding structure of the suitable location to determine the polishing difficulty;

[0232] Based on the difficulty of the polishing, determine whether to use the appropriate position as the gate adjustment position.

[0233] Optionally, when the adjustment module 304 adjusts the simulation parameters according to the gate position adjustment scheme, it is used to:

[0234] Based on the described shrinkage cavity conditions, determine the location of the cooling point;

[0235] Based on the location of the gate and the location of the cooling point, determine the riser adjustment scheme;

[0236] The simulation parameters are adjusted according to the gate position adjustment scheme and the riser adjustment scheme.

[0237] Optionally, when the adjustment module 304 determines the associated location based on the defect location, it is used to:

[0238] The actual heating condition at the defect location is determined based on the casting speed and the initial casting temperature.

[0239] Based on the desired flatness and the casting properties, determine the desired heat level to achieve the desired flatness under the influence of the casting properties;

[0240] The influence range of the defect location is determined based on the temperature change and the expected heat.

[0241] Based on the described scope of influence, determine the associated location.

[0242] The system in this embodiment can be used to execute the methods of any of the above embodiments, and its implementation principle and technical effect are similar, so they will not be described again here.

Claims

1. A method for predicting shrinkage cavity defects in castings based on virtual simulation technology, characterized in that, include: S1. Obtain casting planning information, analyze the casting planning information, and determine simulation parameters, including casting temperature, casting pressure, and initial casting speed; S2. Perform simulation based on the simulation parameters to obtain simulation results, and determine the shrinkage cavity situation based on the simulation results; S3. Obtain casting requirement information, analyze the casting requirement information, and determine the desired flatness; S4. Adjust the simulation parameters according to the shrinkage situation, and repeat step S2 according to the adjusted simulation parameters until the simulation result meets the desired flatness. The step of adjusting the simulation parameters according to the shrinkage condition includes: Based on the described shrinkage cavity situation, the defect location is determined, and the shrinkage cavity situation is analyzed to determine the shrinkage cavity size and actual temperature change at each defect location. Determining the associated location based on the defect location includes: The actual heating condition at the defect location is determined based on the casting temperature and the initial casting speed. Based on the desired flatness and casting properties, determine the desired heat level to achieve the desired flatness under the influence of the casting properties; The influence range of the defect location is determined based on the temperature change and the expected heat. Based on the described scope of influence, determine the associated location; Based on the associated location and the defect location, an adjustment area is determined. The adjustment area is the area where parameters need to be adjusted to resolve the defect problem. The desired temperature is determined based on the size of the shrinkage cavity and the actual temperature change. The simulation parameters are adjusted according to the desired temperature, including: Determine the gate diameter based on the gate location; Based on the gate diameter, the casting structure is analyzed to determine the gate adjustment position, including: Based on the gate diameter, the casting structure is analyzed to determine a suitable location that meets the gate diameter requirement; Analyze the surrounding structure of the suitable location to determine the polishing difficulty; Based on the difficulty of the polishing, determine whether to use the appropriate position as the gate adjustment position; The casting position is determined based on the casting temperature, the initial casting speed, and the desired temperature. Based on the casting position and the gate adjustment position, determine the gate position adjustment scheme; According to the gate position adjustment scheme, the simulation parameters are adjusted, including: Based on the described shrinkage cavity conditions, determine the location of the cooling point; Based on the location of the gate and the location of the cooling point, determine the riser adjustment scheme; The simulation parameters are adjusted according to the gate position adjustment scheme and the riser adjustment scheme.

2. The method according to claim 1, characterized in that, The analysis of the casting planning information and the determination of simulation parameters include: Analyze the casting planning information to determine the location of the gating gate, gating system, and riser. Obtain casting information to determine casting properties and structure; The simulation parameters are determined based on the casting properties, casting structure, gate location, gating system location, and riser location.

3. The method according to claim 2, characterized in that, The simulation parameters include casting temperature. Before determining the shrinkage cavity situation based on the simulation results, the method further includes: Based on the casting structure, determine the casting partitioning; Based on the zoning of the casting, the casting data is obtained; Analyze the casting data to determine the temperature changes during the casting process; Based on the temperature changes and the casting temperature, special areas are identified. These special areas are high-risk areas for defect formation, including hot spots, thin walls, complex shapes, and the vicinity of the gate.

4. The method according to claim 3, characterized in that, The step of determining simulation parameters based on the casting properties, casting structure, gate location, gating system location, and riser location includes: Based on the casting structure, determine the structural changes in the special region; Based on the structural changes, the casting dead zone is determined; The casting speed of the casting dead angle is determined based on the gate position and the runner position. The initial casting speed is determined based on the casting speed in the dead zone, the gate position, and the runner position. The cooling method for the casting is determined based on the structural changes described above; The casting temperature and casting pressure are determined based on the initial casting speed and the casting cooling method. The casting temperature, the casting pressure, and the initial casting speed are determined as the simulation parameters.

5. A casting shrinkage cavity defect prediction system based on virtual simulation technology, characterized in that, Applied to the method as described in any one of claims 1-4, comprising: The information analysis module is used to acquire casting planning information, analyze the casting planning information, and determine simulation parameters; The cavity reduction determination module is used to perform simulation based on the simulation parameters, obtain simulation results, and determine the cavity reduction situation based on the simulation results; The requirements analysis module is used to obtain casting requirements information, analyze the casting requirements information, and determine the desired flatness. The adjustment module is used to adjust the simulation parameters according to the hole shrinkage situation, and to repeatedly execute the hole shrinkage determination module according to the adjusted simulation parameters until the simulation result meets the expected flatness.

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