Numerical Simulation and Defect Analysis in the Casting of the Nodular Cast Iron Truck Rear Axle

Abstract

The paper analyzes the reasons of some typical defects such as shrinkage porosity (macro or micro), shrinkage cavity, cold shut, segregation and hot crack which occurring the truck rear axle casing using nodular cast iron during the casting process. A three-dimensional (3D) CAD engineering model is created by the Pro/E software, one 3D FDM (Finite Difference Methods) numerical solidification model and Z-CAST simulation software are used to study the casting solidification of the rear axle casing using nodular cast iron. Based on the simulation research results, the structure design of the truck rear axle casing is improved and the casting technique is developed, these simulations and experiments show that these optimization methods are contribute to reduce the casting defect and improve the product quality.