In order to improve the casting quality of machine tool spindle box

a casting process analysis and design were conducted based on the requirements of sand rapid prototyping technology.The ProCAST simulation software was utilized to numerically simulate the casting process and optimize the casting process

effectively minimizing defects such asshrinkage cavities and porosity.The influence of casting process parameters on porosity was analyzed through a single-factor experiment

followed by the design of a response surface experiment utilizing the Box-Behnken method to obtain a regression model between casting process parameters and porosity.Variance and confidence analysisresults showed that the mathematical model fits well and the data reliabilitywas high.Using genetic algorithms for the optimization design of casting process parameters

the combination of parameters that minimizes porosity was identified as a casting temperature of 1 360 ℃

casting time of 23 s

and mold temperature of 24 ℃.Experimental results showed that the deviation between the predicted value and the experimental value was 0.38%

and the porosity was reduced by 4.2% compared with pre-optimization levels

confirming the effectiveness of the model predictions and optimization results.This research provides a technical reference for the casting process design of machine tool castings based on sand rapid prototyping technology.