Engineering of critical cast parts made of high-strength cast iron based on world experience. Report 1. Development of casting manufacturing technology and computer simulation of casting processes

The article addresses the critical challenge of import substitution in foundry production by developing an innovative technology for manufacturing complex high-strength cast iron components. Using the reproduction of a “Housing” part as a case study, we present a comprehensive solution for producing castings with intricate internal geo-metries under conditions of incomplete technical documentation.The proposed methodology combines advanced 3D sand printing for mold fabrication with sophisticated computer simulation using LVMFlow casting process software. Key technological solutions include: development and optimization of the gating system design to achieve optimal cross-section ratios; development of a feeding system that effectively compensates for the significant shrinkage characteristic of ductile iron solidification; adjustment of the pouring temperature regime from 1260°C to 1420°C to preserve modification effects.Experimental validation confirmed the effectiveness of the proposed solutions: the produced castings demonstrated high-quality formation of complex internal channels, absence of shrinkage defects in critical sections, and compliance of mechanical properties with high-strength cast iron grade requirements. The sand molds from 3D-Fab Sandforms exhibited sufficient strength, low gas generation, and required permeability.The developed approach provides practical value for machinery enterprises facing import substitution challenges. The methodology enables reproduction of complex hydraulic components without original manufacturing data by employing digital production technologies. The research results are particularly relevant under current import restrictions, offering a viable pathway for domestic production of critical components.