Simulation of Casting Process for Ductile Iron Wind Generator Rotor Shaft

Abstract

Casting process of heavy section ductile iron wind generator rotor shaft was simulated by finite element software ProCAST. Gating systems was designed according to the structure of the casting. Solidification behavior of the casting was then analyzed. Defects, especially porosity, of the casting during solidification were predicted and hence casting process optimization has been performed based on the simulation results in order to avoid porosity in the casting. Results show that solidification time of the casting is more than 14h when cooled in sand mold. Porosity easily formed at the thermal center and in the middle of flange. Solidification time is evidently decreased with the help of chills. However, porosity tendency depends on the position of chills. A ductile iron rotor shaft casting with good quality was finally produced according to the simulation results.

Analysis of the influence of the gating system shape on the filling and solidification of ductile iron castings

“…In a similar way we could mention many other studies, e.g. [11][12][13][14][15][16][17][18][19][20][21][22], focused on casting production optimization.…”