NUMERICAL UNDERSTANDING OF CAMPBELL'S CASTING DESIGN RULES

摘要

Casting design, in particular gating/feeder design has a direct influence on the quality of cast components. Numerous efforts have been made to improve the quality of castings and reduce cost and lead time using simulation tools. However, many casting and gating designs are still based on trial-and-error approach. In this paper, Campbell's casting design rules were applied to a test casting for the design of gating and feeder system. A commercial software MAGMASOFT~® was used to simulate the filling process and to predict the quality of test castings with different designs of gating and feeder system. An improved gating and feeder system was achieved by incorporating Campbell's casting design rules with numerical analysis. The results show that with the improved gating and feeder system, the filling process and the quality of the castings have been greatly improved in terms of liquid front damage, bubble damage and porosity.