铸造宏观过程数值模拟技术的研究现状与展望  

Research Status and Prospect on Numerical Simulation Technology of Casting Macroscopic Process

作　　者：廖敦明[1] 曹流[1] 孙飞[1] 陈涛[1] 

机构地区：[1]华中科技大学材料成形及模具技术国家重点实验室,武汉430074

出　　处：《金属学报》2018年第2期161-173,共13页Acta Metallurgica Sinica

基　　金：教育部新世纪优秀人才支持计划项目No.NCET-13-0229;国家数控重大专项项目No.2012ZX04010-031~~

摘　　要：本文综述了铸造宏观过程模拟技术的研究现状。对比了不同流动场模型下铸造充型过程的差别,其中,两相流模型可准确地考虑气相对充型过程的影响。分析了不同应力场模型对铸造应力演变过程的适用程度,并阐明了其发展趋势。说明了适用于铸造宏观过程模拟的物性参数的获取及修正方法,即采用实验手段测量合金成分和液固相线温度,通过物性参数计算软件获得合金物性参数并做适当调整,进而结合测温实验对相关参数进行修正。对比了不同铸造工艺下的边界条件,并对高压铸造工艺(速度进口边界)和定向凝固工艺(辐射换热边界)的边界条件进行了说明。对比了不同网格类型的区别,并结合不同网格类型说明了不同数值求解算法的区别,本文认为自适应六面体网格和混合网格类型更适合于有限体积法(充型过程计算)和有限元法(凝固过程和应力计算)。针对各种铸造缺陷,对其预测模型和分析方法进行了说明,并阐明了其发展趋势。In recent years, with increasingly maturing of computer simulation technology, numerical simulation methods are playing an increasing significant role in casting macroscopic process, and the research status on numerical simulation technologies in casting macroscopic processes is summarized in this paper. The differences in casting filling process discribed using different flow models are compared,and it is found that the two-phase flow model can be used to accurately handle the effect of gas phase on filling process. The applicabilities of different stress models to the evolution process of casting stress are also analyzed. The accessing and correcting method of physical property parameters, which is fit for simulation of casting macroscopic process, is explained. And the method is that the alloy composition and solidus/liquidus temperature are measured by experimental means, then physical property parameters are calculated by relevant softwares and adjusted accordingly, at last, the parameters are corrected according to temperature experiment. The boundary conditions of different casting techniques are listed,and, in addition, the boundary conditions of high pressure die casting（velocity inlet） and directional solidi-fication（radiation heat transfer boundary） are explained specially. The differences of different mesh types are compared, in combination with which the differences of different numerical solution methods are analyzed. The suitable meshes would be adaptive hexahedral mesh and hybrid mesh, because they fit more for finite volume method（calculation for filling process） and finite element method（calculation for solidification and stress evolution processes）. Prediction models and analysis methods of different casting defects are illustrated. In this paper, various methods used in simulation of casting process are introduced,and their application development trends are also predicted. We hope to offer a reliable reference for numerical simulation methods of casting macroscopic process.

关 键 词：铸造 宏观过程 数值模拟 物理模型 边界条件 缺陷预测 

分 类 号：TG244[金属学及工艺—铸造]