Prediction and Control of Casting Defects in High-performance Modified Gray Cast Iron Brake Drums

SUN Heng; FENG Wei; XIAO Shuyi; ZHU Chundong; YU Zhongquan

doi:10.3969/j.issn.1674-6457.2025.10.006

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Journal of Netshape Forming Engineering ›› 2025, Vol. 17 ›› Issue (10) : 64-72. DOI: 10.3969/j.issn.1674-6457.2025.10.006

Iron and Steel Forming

Prediction and Control of Casting Defects in High-performance Modified Gray Cast Iron Brake Drums

SUN Heng¹, FENG Wei^1,*, XIAO Shuyi², ZHU Chundong³, YU Zhongquan⁴

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Abstract

The work aims to study the filling and solidification behavior of high-performance modified gray cast iron brake drums developed by a casting company, establish a finite element model for the casting of modified gray cast iron brake drums, simulate their filling and solidification processes, and achieve the goals of predicting and controlling casting defects, optimizing process parameters and improving product quality. The material properties of the modified gray cast iron were calculated using JMatPro software, and the material model was modified. Based on Procast software, a finite element model was established to analyze the forming process characteristics and shrinkage porosity distribution of modified gray cast iron. Meanwhile, the gating system structure, gating temperature, and gating time were taken as design variables, with shrinkage porosity as the optimization target, to optimize the casting process of the modified gray cast iron brake drum, followed by experimental validation. The results showed that the solid-phase content and density of the modified gray cast iron changed significantly after modification, with the solidus and liquidus temperature decreasing to 1 072 ℃ and 1 190 ℃, respectively. During the casting process, the melt filled the mold from bottom to top in a sequential manner, with no splashing or branch flow convergence, resulting in a good filling process. However, during solidification, isolated liquid-phase regions appeared near the inner gating on the ribs of the workpiece, leading to shrinkage defects. Experimental results were consistent with simulation results. After optimizing the gating system structure and process parameters, the shrinkage porosity of the modified gray cast iron brake drum was reduced to 0.86%, with good molding quality. The optimal gating temperature was found to be 1 425 ℃, and the best gating time was 30 s. Through the integration of material property computations, finite element modeling, and experimental validation, casting defects can be accurately predicted, thereby facilitating the optimization of production processes and contributing to the enhancement of product quality.

Key words

modified gray cast iron / brake drum / numerical simulation / process optimization / shrinkage porosity

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SUN Heng, FENG Wei, XIAO Shuyi, ZHU Chundong, YU Zhongquan. Prediction and Control of Casting Defects in High-performance Modified Gray Cast Iron Brake Drums[J]. Journal of Netshape Forming Engineering. 2025, 17(10): 64-72 https://doi.org/10.3969/j.issn.1674-6457.2025.10.006

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