Numerical simulation and optimization of shell mould casting process for leaf spring

Although the shell mould casting process has a wide range of application in many fields, the prediction of casting defects is still a problem. In the present work, a typical leaf spring bracket casting of ZG310-570 was fabricated by shell mold casting. The finite element model and ProCAST software were utilized for simulating the filling and solidification processes of the casting; and the formation mechanism of the gas pore, and shrinkage porosity defects were analyzed. The results indicate that the gas pore and shrinkage porosity defects are formed due to air entrapment, insufficient feeding and non-sequential solidification. Subsequently, through changing the position of risers, adding a connecting channel between the risers, and setting blind risers at the U-shaped brackets, an optimized gating and feeding system was established to improve the quality of the casting. After optimization, the gas pore and shrinkage porosity defects of the leaf spring bracket casting are effectively eliminated. The experiment results with the optimized casting process are in good agreement with the numerical simulation, which verifies the validity of the finite element model in the shell mould casting.