2 Original process pouring system
Figure 3 Solidification process of the original plan
4 Inner cavity defects 
Figure 5 End face defects
02#
Figure 6 Original casting
Figure 7 Optimized casting
According to the simulation results, in view of the interruption of the feeding channel at the intersection of B and C with the runner, the runner was moved upward and directly connected to B and C. This also reduced the distance between the runner and the upper end of the casting, shortening the Determine the distance that the riser needs to be fed. Since the hot joints at D and E are reduced after the weight of the casting is reduced, changing the four edge risers to have inflection allowances not only facilitates the top-down solidification sequence of the casting, but also reduces the volume of the gating system and shortens the solidification time. It is also conducive to demoulding and can greatly improve process yield and production efficiency. The optimized gating system is shown in Figure 8.
Figure 8 Optimized gating system
plan simulation The optimized scheme is simulated, and the solidification process is shown in Figure 9. During the solidification process, the casting forms a feeding channel through the subsidy, runner, and sprue, and the solidification expansion angle is always toward the direction of the runner, effectively establishing a temperature gradient between the hot section and the riser, and realizing sequential solidification. 
Figure 9 Optimized solution solidification process
Judging from the production verification, the solidification time of the casting is reduced, demolding is easier than the original plan, and there are no casting defects after X-ray inspection. After the casting is processed, the structure of the processed surface is dense and defect-free, and the air tightness test is qualified. The original plan of castings with a gating system weighs 47kg, the process yield rate is 51%, and it takes an average of 20 minutes to produce one piece. The optimized plan has a casting with a gating system of 35kg, the process yield rate is 69%, and it takes an average of 15 minutes to produce one piece. For the same 1 ton aluminum alloy liquid, with a production time of 7 hours, the original plan can produce 21 pieces, and the optimized plan can produce 28 pieces. The optimization plan has greatly improved the process yield and production efficiency, and reduced production costs. The casting produced by the optimized plan is shown in Figure 10. 
Figure 10 Castings produced by the optimized solution
