Abstract: Aiming at the problems of casting sand holes, the slurry eyes and scour defects in the integral casting of the water pump-thermostat housing, the whole set of casting processes and moulds were designed innovatively. Firstly, 3D modeling technology was used to build the structural models of water inlet, water outlet, thermostats and vortex chambe which analyzed the key factor affecting casting quality, determined the fractal process, shrinkage and machining allowance of castings, and preliminary designed an integrated shell casting systems as well. Secondly, the Magma software was used to verify the designed housing, casting moulds, and casting procedure. According to the analysis results, the pouring mould and casting process rules were improved.The results indicate that the temperature of the improved castings is uniform, which has advantages such as no subcooling temperature zone, little risk of defects of cold barrier blowhole, good filling, no isolated liquid zones in the shrinkage processes and obvious hot spot at high temperature places.
Key words: pump shell; thermostat shell; casting process; CAE analysis