基于AnyCasting的M3500蠕铁气缸盖铸造工艺优化
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摘要
铸件充型凝固过程数值模拟是提高铸件质量和铸造生产经济效益的重要途径之一。本文对M3500蠕铁气缸盖铸造工艺现状及缺陷原因进行了分析;并以模拟仿真软件Anycasting为工具,实现了对M3500蠕铁气缸盖铸件充型过程三维数值模拟,同时模拟了铸件凝固过程的温度场,并通过铸件的实际缺陷验证了分析过程和结果的合理性;基于温度场分析结果,依据温度曲线法,温度梯度法和Niyama判据对铸件的缩孔进行了预测;以仿真为手段,研究了M3500气缸盖工艺改进方案,给出了两种工艺改进方法,分别降低了废品率,实现了同时或定向冷却,并通过试验验证了两种方案的有效性。
本文通过数值模拟和实践相结合的方式,研究了M3500蠕铁气缸盖铸造工艺,改进了该气缸盖铸造工艺,减少了废品率,可为其它铸件工艺的优化和改进研究提供参考。
The numerical simulation of mould filling process and casting solidification process is an important method, by which the casting quality and the production economic benefits can be improved. In this thesis, the analysis for the casting status and some defect reason for the vermicular iron cylinder head of YC M3500 was done. The 3D simulation of the filling and solidification process of the casting of the cylinder head, including the temperature field simulation was done by a software tool ,named Anycasting. The validation for the simulation results was done by comparing with the actual casting flaw. From the result of the temperature field, the casting defects have been calculated by the methods of temperature curve, temperature gradient and Niyama. The research for the optimization of the cylinder head casting was done. Two variants of the optimized casting for lowering the casting defect and the real time or directional cooling were given. The test result shows the availability of the variants.
In this thesis, through a combination of numerical simulation and practice, the research for the simulation of the casting process of M3500 vermicular iron cylinder head was done. The optimization improved the casting and lowered the defective index. It can be a reference for other casting process optimization.
本文通过数值模拟和实践相结合的方式,研究了M3500蠕铁气缸盖铸造工艺,改进了该气缸盖铸造工艺,减少了废品率,可为其它铸件工艺的优化和改进研究提供参考。
The numerical simulation of mould filling process and casting solidification process is an important method, by which the casting quality and the production economic benefits can be improved. In this thesis, the analysis for the casting status and some defect reason for the vermicular iron cylinder head of YC M3500 was done. The 3D simulation of the filling and solidification process of the casting of the cylinder head, including the temperature field simulation was done by a software tool ,named Anycasting. The validation for the simulation results was done by comparing with the actual casting flaw. From the result of the temperature field, the casting defects have been calculated by the methods of temperature curve, temperature gradient and Niyama. The research for the optimization of the cylinder head casting was done. Two variants of the optimized casting for lowering the casting defect and the real time or directional cooling were given. The test result shows the availability of the variants.
In this thesis, through a combination of numerical simulation and practice, the research for the simulation of the casting process of M3500 vermicular iron cylinder head was done. The optimization improved the casting and lowered the defective index. It can be a reference for other casting process optimization.
引文
[1]周亘.车用柴油机蠕墨铸铁缸盖铸造工艺探讨.铸造工艺,2003(5):34～38
[2]李培.蠕墨铸铁生产工艺控制及应用.铸造,2002(2):119～120
[3]陈位铭,金胜灿. SinterCast蠕墨铸铁的大规模生产.汽车工艺与材料, 2005(5):20～23
[4]周鸿鹏,杨光萍等.蠕墨铸铁生产工艺控制.山东冶金,2005(8):20～21
[5]国家职业资格培训教材审编委员会.铸造工(技师、高级技师).机械工业出版社,2006
[6]柳百成,荆涛.铸造工程的模拟仿真与质量控制.机械工业出版社,2001
[7]孙逊,安阁英等.铸件充型凝固过程数值模拟发展现状.铸造, 2000(2):84～88
[8]柳百成.铸件充型凝固过程数值模拟国内外研究进展.铸造, 1998(4):40～50
[9]荆涛.凝固过程数值模拟.北京:电子工业出版社,2002
[10]齐慧.铸件流场与温度场耦合计算的数值模拟研究.[硕士学位论文].成都:四川大学,2002
[11] R A Stoehr,W S Hwang. Modelling the Flow of Molten Metal Having a free surface during Entry into Molds[A]. proceeding of international conference on Modeling of Casting and Welding processⅡ[C]. The Metallurgical Society of ALME.1983,47~58
[12] W. S. Hwang. Computer Simulation for the Filling of Casting. AFS, 1987, 141, pp425～430
[13]张舒娟,侯华等.充型过程的数值模拟技术.材料导报,2007(3):104～107
[14]王旭波.铸件充型过程三维数值模拟. [硕士学位论文].山东:山东大学,2005
[15] M Cross, J compbell. [A]. odeling of Casting, Welding and Advanced Solidification Processes VI, Proceedings of International Conference[C]. PalmCoast, USA: The Minerals, Metals & Materials Society, 1993.337～492
[16]白月龙.低压铸造充型过程数值模拟研究. [硕士学位论文].太原:华北工学院,2002
[17]张光跃,熊守美.铸件充型过程数值模拟的实验验证及工程应用.铸造,2000(10):775～779
[18] B G Thomas, C Beckermann. [A]. Modeling of casting, Welding and Advanced Solidification Processes VIII, Proceedings of International Conference [C]. San Diego, USA: The Minerals, Metals & Materials Society, 1998.17～132
[19]杨全,张真.金属凝固与铸造过程数值模拟.浙江大学出版社,1996
[20]华铸CAE/InterCAST铸造工艺分析软件集成系统分析指南
[21]邱宗文.铸件凝固过程温度场三维数值模拟软件开发. [硕士学位论文].南京:东南大学,2004
[22]李德群,李阳等.材料成形过程模拟技术及其应用.中国机械工程,2006(10):2005～2009
[23]刘军利,李日等.基于ProCAST的消失模铸造工艺研究.铸造设备研究,2006(4):24～26
[24]晋艳娟,崔小朝.铝板坯半连续铸造充型过程三维流场与温度场耦合数值模拟.太原科技大学学报,2006(6):217～220
[25]中国机械工程学会铸造分会代表团. 21世纪铸造工业技术展望-第九届国际铸造博览会概览.铸造,1999(10):1～3
[26] Anycasting软件产品介绍
[27]熊守美,许庆彦,康进武.铸造过程模拟仿真技术.机械工业出版社,2007
[28]楼志城.冶金传输现象的基本原理与方法.上海:上海科学技术出版社,1997
[29]贺鸿志等.传输过程数值模拟.北京:冶金工业出版社,1998
[30]曹兴旺.离心铸造充型过程数值模拟的研究. [硕士学位论文].武汉:华中科技大学,2004
[31]陈义良.湍流的计算模型.北京:中国科技大学出版社,1991
[32]陶文铨.数值传热学.西安:西安交通大学出版社,1988
[33]王文清,李魁盛.铸造工艺学.北京:机械工业出版社,1997
[34]李隆盛.铸造合金及熔炼.北京:机械工业出版社,1989
[35]林惠娟,黄文星.铸造上浇注过程的电脑辅助流动分析.铸工(台湾),1987,54:1～8
[36]卢文华,李隆盛,黄良余.铸造合金及其熔炼.北京:科学出版社,2001
[37]贾良荣,熊守美等.压力铸造充型过程流动与传热数值模拟的研究.清华大学学报,2001(41):8～11
[38]王冬,李玉梅等.铸造过程补缩机理及其数学模型.铸造,1996(2):13～16
[39]吴子牛.计算流体力学基本原理.北京:科学出版社,2001
[40]廖日东,刘金祥.柴油机机体铸造充型过程有限元模拟.铸造技术,2006(10):1115～1117
[41]中国机械工程学会铸造分会.铸造手册(铸铁).北京:机械工业出版社,2004
[2]李培.蠕墨铸铁生产工艺控制及应用.铸造,2002(2):119～120
[3]陈位铭,金胜灿. SinterCast蠕墨铸铁的大规模生产.汽车工艺与材料, 2005(5):20～23
[4]周鸿鹏,杨光萍等.蠕墨铸铁生产工艺控制.山东冶金,2005(8):20～21
[5]国家职业资格培训教材审编委员会.铸造工(技师、高级技师).机械工业出版社,2006
[6]柳百成,荆涛.铸造工程的模拟仿真与质量控制.机械工业出版社,2001
[7]孙逊,安阁英等.铸件充型凝固过程数值模拟发展现状.铸造, 2000(2):84～88
[8]柳百成.铸件充型凝固过程数值模拟国内外研究进展.铸造, 1998(4):40～50
[9]荆涛.凝固过程数值模拟.北京:电子工业出版社,2002
[10]齐慧.铸件流场与温度场耦合计算的数值模拟研究.[硕士学位论文].成都:四川大学,2002
[11] R A Stoehr,W S Hwang. Modelling the Flow of Molten Metal Having a free surface during Entry into Molds[A]. proceeding of international conference on Modeling of Casting and Welding processⅡ[C]. The Metallurgical Society of ALME.1983,47~58
[12] W. S. Hwang. Computer Simulation for the Filling of Casting. AFS, 1987, 141, pp425～430
[13]张舒娟,侯华等.充型过程的数值模拟技术.材料导报,2007(3):104～107
[14]王旭波.铸件充型过程三维数值模拟. [硕士学位论文].山东:山东大学,2005
[15] M Cross, J compbell. [A]. odeling of Casting, Welding and Advanced Solidification Processes VI, Proceedings of International Conference[C]. PalmCoast, USA: The Minerals, Metals & Materials Society, 1993.337～492
[16]白月龙.低压铸造充型过程数值模拟研究. [硕士学位论文].太原:华北工学院,2002
[17]张光跃,熊守美.铸件充型过程数值模拟的实验验证及工程应用.铸造,2000(10):775～779
[18] B G Thomas, C Beckermann. [A]. Modeling of casting, Welding and Advanced Solidification Processes VIII, Proceedings of International Conference [C]. San Diego, USA: The Minerals, Metals & Materials Society, 1998.17～132
[19]杨全,张真.金属凝固与铸造过程数值模拟.浙江大学出版社,1996
[20]华铸CAE/InterCAST铸造工艺分析软件集成系统分析指南
[21]邱宗文.铸件凝固过程温度场三维数值模拟软件开发. [硕士学位论文].南京:东南大学,2004
[22]李德群,李阳等.材料成形过程模拟技术及其应用.中国机械工程,2006(10):2005～2009
[23]刘军利,李日等.基于ProCAST的消失模铸造工艺研究.铸造设备研究,2006(4):24～26
[24]晋艳娟,崔小朝.铝板坯半连续铸造充型过程三维流场与温度场耦合数值模拟.太原科技大学学报,2006(6):217～220
[25]中国机械工程学会铸造分会代表团. 21世纪铸造工业技术展望-第九届国际铸造博览会概览.铸造,1999(10):1～3
[26] Anycasting软件产品介绍
[27]熊守美,许庆彦,康进武.铸造过程模拟仿真技术.机械工业出版社,2007
[28]楼志城.冶金传输现象的基本原理与方法.上海:上海科学技术出版社,1997
[29]贺鸿志等.传输过程数值模拟.北京:冶金工业出版社,1998
[30]曹兴旺.离心铸造充型过程数值模拟的研究. [硕士学位论文].武汉:华中科技大学,2004
[31]陈义良.湍流的计算模型.北京:中国科技大学出版社,1991
[32]陶文铨.数值传热学.西安:西安交通大学出版社,1988
[33]王文清,李魁盛.铸造工艺学.北京:机械工业出版社,1997
[34]李隆盛.铸造合金及熔炼.北京:机械工业出版社,1989
[35]林惠娟,黄文星.铸造上浇注过程的电脑辅助流动分析.铸工(台湾),1987,54:1～8
[36]卢文华,李隆盛,黄良余.铸造合金及其熔炼.北京:科学出版社,2001
[37]贾良荣,熊守美等.压力铸造充型过程流动与传热数值模拟的研究.清华大学学报,2001(41):8～11
[38]王冬,李玉梅等.铸造过程补缩机理及其数学模型.铸造,1996(2):13～16
[39]吴子牛.计算流体力学基本原理.北京:科学出版社,2001
[40]廖日东,刘金祥.柴油机机体铸造充型过程有限元模拟.铸造技术,2006(10):1115～1117
[41]中国机械工程学会铸造分会.铸造手册(铸铁).北京:机械工业出版社,2004
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