【文章內(nèi)容簡介】 of water pump is produced in an IP 550 horizontal die casting machine. There are two types of defects occurring in this casting: air holes and porosity. The metal flow and solidification in the dies is simulated with the use of MAGMASOFT software. The simulation results of several technological scheme are analyzed. The problems occurring in the metal flow and solidification can be observed directly through the simulation. In the original scheme the gating system of the water pump causes the splash of liquid metal and air entrapment during filling (shown in Fig. 4). This results in the occurrence of air holes and oxide inclusions. Then the design of the gating system is revised and the process parameters are also regulated, which reduces these defects notably (shown in Fig. 5). In addition, the original scheme often leads to porosity at the hot spot of die castings (shown in Fig. 6). Therefore, in the revised scheme the transition point from the slow shot to plunger acceleration is adjusted suitably, and the pressure buildup time is also shortened, in order that the high pressure can be transferred to the liquid metal at the hot spots in time before the gate solidifies. Thus, the defects of porosity are basically eliminated. The plex shape of the water pump casting and its wall unevenness make the defects of porosity and air entrapment easy to occur, but the demand for the sealing of a die casting of a water pump is very high, and the casting has to pass through a hydraulic pressure test without any leakage. The design of the die casting process is optimized with the help of CAE simulation and analysis, and the percentage of qualified products of die casting is raised greatly in a shorter time. . The realization of CAM On the basis of the data of the 3D solid modeling of the cavities of die casting dies, with the use of the Pro/MANUFACTURING module of the Pro/ENGINEER CAD/CAM software, the 3D solid modeling of blank figures of the inlays are created first. Then the operation table of the machining including the machining parameters, cutters, cutter path, etc. is listed, and the NC (numerical control) cutting procedures and the CL (cutter locate) data files are also created. Furthermore due to the use of the module of an NCcheck, the cutter path in machining is checked and the instantaneous machining process can be visualized. The CL data file of each NC cutting procedure is revised until a satisfactory result is reached. The CAM is realized as soon as these data files are postprocessed and transferred into the NC machine code. The cutter path in the machining of the inlay of die casting dies of housing cover is shown in Fig. 7. 4. Results of the application of integrated system As mentioned above, with the help of the Pro/ENGINEER CAD/CAM software and a primary expert system package, the 3D solid modeling of die casting and the design of technological scheme of die casting process are created. Next the simulation and analysis of metal flow and solidification in dies are performed with the use of the MAGMASOFT software。 the technological scheme and process parameters of die casting are also revised and optimized. Then the 3D solid modeling of whole set of dies is pleted. Finally the CAM machining data of the plex surface of moulds and cor