Abstract
Problem Statement: This article analyses the current state of optimization tasks in designing casting processes for the production of shaped steel castings intended for critical applications. The main areas of potential research include geometrical and topological optimization of casting technology with the help of finite element methods. The article also describes some basic approaches to the selection of objective function and a set of functions for optimization, which is necessary in order to obtain excellent mechanical properties in steel castings and to design technological castings with high resistance to external loads. Objectives: The cast body of a flangeless check valve designed for ship industry and for common industrial use was chosen as the object of this research. Methods Applied: The objective functions applied for the optimization included the local parameter of the direction of solidification and a set of calculated criteria responsible for the local deficiency of liquid metal feed. The methods developed are based on iterative simulation of the solidification process and the control volume method. A different geometry of ingot tops and the gating system was used for each iteration depending on the assigned objective function. A series of passes was performed, with each pass slightly changing the geometry of the part. The result of each new pass was compared with the previous one until the satisfactory result was achieved. The article describes the results of topological optimization done to the casting. Practical Relevance: The casting process was modified, which resulted in a new design ensuring a high-quality casting with no deterioration of the mechanical properties. The mechanical properties were tested with the help of samples. The calculations and the results of direct mechanical testing show that the flangeless cast body can offer a high performance and the required rigidity.
Keywords
Steel castings, topological optimization, geometrical optimization, shut-off valves, casting technology, life cycle.
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