铸造充型过程气液两相流动数值模拟的研究
摘要
气液两相流动数值模拟技术是近几年来计算流体力学(CFD)领域研究的热点和前沿。本研究将计算流体力学最新方法,应用于铸造充型过程气液两相流动的数值模拟,对于深化铸造仿真技术和提高预测水平具有重要的理论意义和实际应用价值。
精确描述相间运动界面的变化是模拟铸造充型过程气液两相流动的前提和基础。本研究采用新的界面追踪技术Level Set方法描述铸造气液两相界面,并利用高精度离散格式求解界面输运方程。在此基础上,发展了新的适用于铸造充型过程气液两相流动的SOLA-Level Set算法。该算法改进了传统的SOLA方法使其具备求解可压缩气体运动方程的能力,使用Ghost Fluid方法解决了气液两相界面处密度跨越较大易引起的计算发散问题。
为了验证本研究算法模拟铸造气液两相流动的能力,采用了实验验证与软件验证相结合的方法。利用水力学相似原理设计了水模拟实验方案,实验与计算结果基本一致,表明该算法可以准确处理气液两相流动过程中的复杂界面变化,能够适用于密度跨越较大的气液两相流动计算。利用现有商业化软件FLUENT与自行开发系统进行模拟对比,验证了自行开发系统的正确性和可靠性。
高温液态金属的充型过程总是伴随着热量的散失,欲准确模拟铸造气液两相流动过程,流动场与温度场耦合计算是必需的。本文建立了铸造气液两相流动场与温度场耦合计算的数学模型,编制了铸造气液两相流动传热耦合软件。
为了检验本文算法在三维复杂边界条件下的稳定性和可靠性,并分析两相流计算与单相流计算的异同,采用国内知名铸造商业软件华铸CAE进行计算对比。分别采用华铸CAE和本文算法对实际铸件的生产工艺进行了模拟分析,对比两种计算的充型过程,表明气液两相流动算法能够准确模拟形状较为复杂的实际铸件的充型过程,该算法不仅反映了型腔背压对液体流动的影响,而且可以定量预测卷气形成过程,比单相流计算更能准确再现铸造充型过程的复杂现象。本文提出的气液两相流动数值模拟方法对铸造生产具有较强的理论意义和实用价值。
The gas-liquid two-phase flow (GLTF) simulation is an advancing research on Computational Fluid Dynamics (CFD). Based on the application of the latest technique of CFD, the simulation of GLTF during the mold filling process is developed in this research, which has a great meaning on improving casting simulation technique.
Precisely describing the interface movement is the key and basis to the GLTF simulation during mold filling process. Level Set method, which adopts high order discrete schemes, is a new interface tracking method developed in recent years. In this study, Level Set is introduced to simulate the interface movement between the gas and the liquid. And the GLTF during mold filling process is modeled by the combination of SOLA and Level Set, in which the conventional algorithm SOLA is modified to calculate the compressible gas movement, and Ghost Fluid Method is adopted to deal with the problem of large jump in density across the interfaces.
The validity of the presented method is verified by experiments and commercial CFD software. Firstly, water analog experiments based on similarly laws are carried out. Comparison between experimental and simulation results shows that the self-developed method is efficient to deal with complex interfaces movement, and also suitable for the calculation with large density jump. And then, the simulation results are compared with that by the commercial CFD software FLUENT, which confirms that this study has a good reliability.
The casting process involves coupled effects of fluid flow and heat transfer. In order to simulate the mold filling process properly, heat transfer during the fluid flow must be taken into account. Therefore, a numerical simulation program coupling fluid field and temperature field of GLTF during casting process has been developed.
Finally, using the commercial casting software InteCast CAE to simulate the complex 3-D castings, and compare the results with that of self-developed method, the reliability and validity of this study can be further tested. It can be found that the method in this study can correctly simulate the complex filling process of 3-D castings, and furthermore, the effect of backpressure on the liquid metal, and also the air entrapment during the filling process, can be quantificationally simulated in this study. Therefore, the presented method for GLTF has a profound meaning on casting production.
精确描述相间运动界面的变化是模拟铸造充型过程气液两相流动的前提和基础。本研究采用新的界面追踪技术Level Set方法描述铸造气液两相界面,并利用高精度离散格式求解界面输运方程。在此基础上,发展了新的适用于铸造充型过程气液两相流动的SOLA-Level Set算法。该算法改进了传统的SOLA方法使其具备求解可压缩气体运动方程的能力,使用Ghost Fluid方法解决了气液两相界面处密度跨越较大易引起的计算发散问题。
为了验证本研究算法模拟铸造气液两相流动的能力,采用了实验验证与软件验证相结合的方法。利用水力学相似原理设计了水模拟实验方案,实验与计算结果基本一致,表明该算法可以准确处理气液两相流动过程中的复杂界面变化,能够适用于密度跨越较大的气液两相流动计算。利用现有商业化软件FLUENT与自行开发系统进行模拟对比,验证了自行开发系统的正确性和可靠性。
高温液态金属的充型过程总是伴随着热量的散失,欲准确模拟铸造气液两相流动过程,流动场与温度场耦合计算是必需的。本文建立了铸造气液两相流动场与温度场耦合计算的数学模型,编制了铸造气液两相流动传热耦合软件。
为了检验本文算法在三维复杂边界条件下的稳定性和可靠性,并分析两相流计算与单相流计算的异同,采用国内知名铸造商业软件华铸CAE进行计算对比。分别采用华铸CAE和本文算法对实际铸件的生产工艺进行了模拟分析,对比两种计算的充型过程,表明气液两相流动算法能够准确模拟形状较为复杂的实际铸件的充型过程,该算法不仅反映了型腔背压对液体流动的影响,而且可以定量预测卷气形成过程,比单相流计算更能准确再现铸造充型过程的复杂现象。本文提出的气液两相流动数值模拟方法对铸造生产具有较强的理论意义和实用价值。
The gas-liquid two-phase flow (GLTF) simulation is an advancing research on Computational Fluid Dynamics (CFD). Based on the application of the latest technique of CFD, the simulation of GLTF during the mold filling process is developed in this research, which has a great meaning on improving casting simulation technique.
Precisely describing the interface movement is the key and basis to the GLTF simulation during mold filling process. Level Set method, which adopts high order discrete schemes, is a new interface tracking method developed in recent years. In this study, Level Set is introduced to simulate the interface movement between the gas and the liquid. And the GLTF during mold filling process is modeled by the combination of SOLA and Level Set, in which the conventional algorithm SOLA is modified to calculate the compressible gas movement, and Ghost Fluid Method is adopted to deal with the problem of large jump in density across the interfaces.
The validity of the presented method is verified by experiments and commercial CFD software. Firstly, water analog experiments based on similarly laws are carried out. Comparison between experimental and simulation results shows that the self-developed method is efficient to deal with complex interfaces movement, and also suitable for the calculation with large density jump. And then, the simulation results are compared with that by the commercial CFD software FLUENT, which confirms that this study has a good reliability.
The casting process involves coupled effects of fluid flow and heat transfer. In order to simulate the mold filling process properly, heat transfer during the fluid flow must be taken into account. Therefore, a numerical simulation program coupling fluid field and temperature field of GLTF during casting process has been developed.
Finally, using the commercial casting software InteCast CAE to simulate the complex 3-D castings, and compare the results with that of self-developed method, the reliability and validity of this study can be further tested. It can be found that the method in this study can correctly simulate the complex filling process of 3-D castings, and furthermore, the effect of backpressure on the liquid metal, and also the air entrapment during the filling process, can be quantificationally simulated in this study. Therefore, the presented method for GLTF has a profound meaning on casting production.
引文
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