Validação do sistema de alimentação de um componente mecânico fundido por meio de simulação de solidificação

Abstract

Metal casting consists of filling an existing cavity, the mold, with a liquid metal to form the geometry of the final cast part after solidification. With the advance of technology, the foundry industries have suffered significant changes in the supply profile of their products. The optimization of the production process allied to the use of computational solidification simulation tools is of enormous value in the modernization of the manufacturing process of castings. Thus, this work has as its primary objective to use the solidification simulation to validate the feeding system of a mechanical component cast in nodular cast iron FE50007. An agricultural part was the component under study. From the 3D model of this part, the Chvorivov modulus calculations were performed, the channel system and riser were dimensioned, and finally, the solidification simulations were developed. The solidification simulations performed used two methods, the Finite Element Method (FEM) and the Finite Difference Method (FDM), using three mesh thicknesses (3.5, 2.5, and 1.5 mm) and two risers diameters with equal heights of 1.5D (57 and 49 mm diameter). No simulation showed porosity above 1% due to the correct sizing of the feeding system and riser. The chosen diameter of the pellet corresponds to the minor diameter (D) = 49 mm because it resulted in a better metallurgical yield of the assembly. Due to the high solidification time, the best software for the simulation was NovaFlow & Solid with the Finite Difference Method (FDM) compared to other software used Altair Inspire Cast with the Finite Element Method (FEM).