Numerical simulation and defect elimination in the casting of truck rear axle using a nodular cast iron

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 take place in the casting processing by applying nodular cast iron to the truck rear axle. A three-dimensional (3D) Computer Aided Design (CAD) engineering model is established by using the Pro/E software, one 3D Finite Difference Methods (FDM) numerical solidification model and Z-CAST simulation software are used to study the casting solidification of the rear axle, which is made from nodular cast iron. Based on the simulation, the casting structure design of the truck rear axle is improved, the casting technique is developed. Many experiment results of the new product show that these optimization methods are very helpful to reduce the casting defect and to improve the product quality.

Research highlights
► A 3D CAD engineering model and FDM model are established to study nodular cast iron solidification.
► Numerical simulation and experimental methods are used to analysis the casting solidification of the rear axle.
► Based on the simulation, the casting structure design and processes of the truck rear axle are improved.
► The product shows the improving pouring system is very helpful to reduce the casting defect.