Using Polygon Soft at the Dimal plant, modeling of the gearbox casing casting is carried out

2021: Simulation of "Gearbox housing" casting using "Polygon Soft"

CSoft Group of Companies on March 13, 2021 announced that using the Polygon Soft system at the Dimal Kirov Electromagnet Plant, the Gearbox Body casting is simulated.

The main task in the manufacture of small batches of castings is to produce them as soon as possible with the minimum cost of developing technology and preparing production. It was this task that had to be solved during the development of the Gearbox Body casting, made of 35L steel using casting technology according to gasified models.

Control operations after manufacturing of the first casting revealed shrinkage shells and porosity in the places of the gearbox cover adjoining. After that, it was decided to abandon field experiments, and determine the reasons for the failure using the Polygon Soft computer modeling system of casting processes. The company was granted a temporary license for this software, and the foundry specialists performed all the work on changing the technology on their own.

Fig. 1. Casting solidification pattern (percentage of liquid phase)

Fig. 2. Porosity distribution in casting

Modeling and analysis of the technology in SKM LP Polygon Soft showed that with the existing structure of the runner-feed system (Fig. 1, 2), solidification is inevitably associated with the appearance of such problems. Based on the results of research, the design of the foundry unit was developed, which ensured the absence of defects in the places where the cover adjoins the body. The size and location of the profits were determined during a series of numerical experiments without refining the model tooling and manufacturing experimental batches of castings.

Fig. 3. Generation of heat nodes in profit (percentage of liquid phase)

Fig. 4. Distribution of porosity in casting with profit

Fig. 5. Finished castings made using new technology

When the simulation at the Polygon Soft LP CMS showed the desired shrinkage pattern with the changed design of the casting unit (Fig. 3, 4), the model tooling was refined, and then an experimental batch of castings was made with their subsequent machining and defect control. The results obtained (Figure 5) allowed this technology to be put into production. The order was completed on time and with minimal costs, the company received the expected profit.