Simulation optimization design of lost foam casting for a large-scale thin-walled aluminum casting platform

As a key component of the gypsum printer, due to its large size and thin-walled structure characteristics, the aluminum casting platform faces challenges such as difficult mold filling and prone to crack formation during the casting process. Traditional casting methods have limitations. By leveraging computer software, especially ProCAST software, a finiteelement simulation-based optimization design of its casting process is carried out. Firstly, the A356 aluminum alloy material used for the casting and the original pouring process plan are elaborated. Through simulation analysis, it is found that the original plan has a high tendency of hot cracking near the gates and risers during the solidification and cooling process. Subsequently, an optimized process plan is proposed, which adopts a four-gate and six-riser scheme and adds vent holes. After optimization, the mold-filling process becomes more stable, the stress distribution is more uniform, the crack tendency is reduced, and the casting quality is improved. This research provides an effective optimization method and theoretical support for the lost foam casting of large-scale thin-walled aluminum casting platforms. Although there are limitations in not considering some complex factors in actual production, it contributes to improving production efficiency, product quality, and reducing production costs.