Modeling of Casting Deformation Prediction During Investment Casting Based on Geometry Dependence

Investment castings have excellent mechanical properties and high surface finish, thus playing an important role in the aerospace industry. However, the unreasonable tooling allowances have led to significant deviations from tolerances and low qualification rates of castings. To solve this problem, we developed a casting deformation prediction model during investment casting. First, the numerical simulation and experiment of the double H-shaped castings were carried out, and the distribution of temperature and displacement fields was analyzed. Then, the experimental deformation results confirmed that the method of shell removal simulation based on solidification could further enhance the simulation accuracy. Moreover, the optimization of simulated results resulted in a 17.65% improvement in deformation prediction accuracy. Finally, the investigation delved into the influence of casting geometrical factors, such as shape, deformation center, constraint degree, and size, on the casting deformation error. Furthermore, the deformation prediction model based on geometry dependence was established. The predictive results closely aligned with the experimental results, attaining an accuracy of 87.39%. Thus, the model is beneficial for production practice and can be applied to provide a more rational tooling allowances. The paper also contributes theoretical support for advancing dimensional accuracy control technology, especially for more intricately shaped castings.