Pressure shell castings are used in many fields of fluid engineering. According to the structural characteristics of pressure shell castings, first based on its CAD drawing, UG software was used to carry out three-dimensional modeling of the casting, and then the casting process plan was designed, and the process plan was optimized using the numerical simulation software ProCAST, and the filling of the casting was analyzed. Process, solidification process, shrinkage cavity, shrinkage defect distribution, etc., and finally determined the best casting process plan for pressure shell castings. Resin sand is used to process sand molds and sand cores with a digital moldless precision casting forming machine, and then molds are fitted, molten metal is smelted, and actual pouring is carried out. Trial production of pressure shell castings is carried out. The obtained castings fully meet the technical requirements of the drawings, which lays a technological foundation for the next step of pilot production of the pressure shell castings by gravity casting method, and also provides a certain reference for the casting process design of other pressure shell castings.
Pressure shell castings are widely used in the field of practical engineering. Its main function is to convert the kinetic energy of the fluid into pressure by sucking fluid into its interior, so as to achieve its overall pressure balance. Therefore, pressure shell castings need to have a certain strength. And before use, the water pressure strength test and the air pressure leakage test should be carried out. Since pressure shell castings are hollow inside, sand cores are required to form them. Digital moldless precision casting forming technology does not need to manufacture molds or patterns. It has the characteristics of short production cycle, low process trial production cost, high degree of digitization, and good green degree. It is especially suitable for process development and production trial production of castings. In this paper, using CAD/CAE/CAM technology and digital moldless precision casting forming technology, the three-dimensional modeling, casting process design and optimization of aluminum alloy pressure shell castings are carried out, and the production trial production is finally carried out.