Ductile iron crossbeam integrated parts casting process and shrinkage analysis

A composite component has been developed to replace the conventional multi-part crossbeam assembly, with its sand casting technique optimized for truck chassis.Computational modeling and experimental methods are employed to simulate the sand casting process, focusing on filling, solidification, temperature distribution, liquid phase dispersion, and shrinkage.The study also fine-tunes the quantity and placement of risers.To minimize defects, the casting parameters are set as follows: pouring temperature of 1380 C, pouring speed of 10 cm/s, and mold preheating temperature of 20 C.This optimized process resulted in a 9.36% reduction in shrinkage compared to the original design.Experimental results indicate that the castings exhibit a spheroidization grade of 2, pearlite content 90%, tensile strength 854 MPa, elongation 6%, and are free from cracks and shrinkage in the critical load-bearing sections, thus meeting the required application standards.