Application of Numerical Simulation on Eliminating Shrinkage Cavity of Ductile Iron Differential Case

A casting process of car differential case has been designed before InteCAST software was used for numerical simulation of the mould filling process and solidification process of ductile iron differential case.Based on simulation results,the tendency and cause of formation of shrinkage cavity in castings under this program have been forecasted and analyzed then the optimization program of riser feeding system was made,which was successful in eliminating the shrinkage defects which were generated during the casting process of differential case.The results indicated that the use of CAE computer simulation technology was helpful to providing appraisement and optimization of process program with dependable reference,shortening trial production cycle,reducing rejection rate hence ensuring the casting quality.