Casting Process Optimization for Large Lower Frame Body of Heavy Gyratory Crusher Based on DOE

doi:10.3901/JME.2017.06.088

Abstract

Abstract: In the casting of the large lower frame bodies for heavy gyratory crushers, many shrinkage defects are frequently generated in these steel castings, so the quality of them cannot be satisfied. The research indicates that whether the shrinkage defects are formed in them is mainly dependent on the process parameters such as the type of risers on the inner part of the casting, the pads of risers on the inner and outer parts of the casting, the type of riser pads, and the pouring temperature. Based on the principle of design of experiment (DOE), considering the above-mentioned four process parameters as the influence factors, a L9(34) orthogonal test scheme was designed to optimize the casting process of the large lower frame body for heavy gyratory crushers, aiming at two test indexes, i.e. the volume of casting shrinkage defects to be minimal and the process yield to be maximal. With the CAE software of ProCAST, nine groups of casting process programs in the L9 (34) orthogonal test scheme were calculated and simulated. By analyzing the simulation results, the optimized casting process was put forward for the large lower frame body of the heavy gyratory crusher, i.e. the inner part of the casting is fed with four cylindrical exothermic risers, the pads of risers are used both on the inner and outer parts of the casting, and the pouring temperature is 1 560 ℃. And the results of the practical casting experiments show that it can not only reduce the shrinkage defects to the greatest extent but also improve the process yield by using DOE method to optimize the foundry process of this large steel casting.

Key words: design of experiment, orthogonal test, process yield, shrinkage defect, large steel casting

XIANG Qingchun, ZHANG Wei, QIU Keqiang, SUN Zhiguo, SUN Aixin, YANG Guixing. Casting Process Optimization for Large Lower Frame Body of Heavy Gyratory Crusher Based on DOE[J]. Journal of Mechanical Engineering, 2017, 53(6): 88-93.

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