Application of numerical simulation during the development of ductile iron bearing seat

The study deals with the casting defects of shrinkage and dispersed shrinkage appeared during the development of ductile iron bearing seat due to the original process of conventional side-riser feeding on the basis of general casting design method. The bearing seat was cast using automatic air-impact moulding production line with green-sand. The commercial software of InteCAST was used to simulate casting solidification process and to analyse the reason for the casting defects. Further, the optimised process was proposed in conjunction with three pieces of arc-type chills and a side-rider every casting. The result of mass production shows that the casting defects of bearing seat were effectively eliminated by the optimised process. Consequently, the development cycle of bearing seat was significantly shortened and business opportunities of new market are obtained for the foundry enterprise.