采煤机齿轨铸件铸造过程模拟及工艺创新设计  

Shearer tooth rail casting process simulation and process innovation design

作　　者：王成军 余汉伟[1,2] 张子鹏 WANG Chengjun;YU Hanwei;ZHANG Zipeng(State Key Laboratory of Mining Response and Disaster Prevention and Control in Deep Coal Mines,Huainan 232001,China;College of Mechanical Engineering,Anhui University of Science and Technology,Huainan 232001,China)

机构地区：[1]深部煤矿采动响应与灾害防控国家重点实验室,安徽淮南232001 [2]安徽理工大学机械工程学院,安徽淮南232001

出　　处：《煤炭科学技术》2020年第2期164-170,共7页Coal Science and Technology

基　　金：安徽省自然科学基金面上资助项目(1708085ME98);国家创新方法工作专项资助项目(2018IM010500)

摘　　要：针对采煤机齿轨在作业中常出现断裂、销孔破坏等失效现象,为提高采煤机齿轨铸件的力学性能,保证采煤工作顺利进行,需要对齿轨铸件的铸造成型过程进行深入分析,寻求最优的铸造工艺方案。以五节距齿轨为研究对象,运用ProCAST软件对齿轨铸件的铸造过程进行数值模拟,通过对齿轨铸件凝固过程和孤立液相区的模拟结果进行分析,预测出齿轨铸件凝固后产生缩松缩孔缺陷的位置。运用TRIZ理论对齿轨铸件产生缺陷的原因进行因果分析,并采用物-场模型创新解决工具提出齿轨铸件工艺优化方案-倾斜浇注工艺方案:倾斜模样造型,浇注时砂箱与直浇道不倾斜;或浇注时将型腔与砂箱、直浇道保持同步倾斜。运用ProCAST软件对2种工艺方案进行模拟仿真,结果表明:齿轨铸件内部缩松缩孔缺陷均得到较大改善,但方案一不利于开模造型,且增加了砂箱的高度;方案二增加了浇注液对直浇道的冲刷,易引起夹砂。结合2种工艺方案的优点,得到最终的优化方案:将模样水平放置造型,浇注时再将型腔与砂箱同步倾斜,保持直浇道竖直状态。运用ProCAST软件对优化后的倾斜浇注工艺方案进行模拟仿真,结果表明:该方案可使齿轨铸件在凝固过程中保持递增的温度梯度,有效促进齿轨铸件实现顺序凝固,提高了组织致密性,明显改善了缩松缩孔缺陷,缩松缩孔体积由2.2%降低为0.052%。In view of the failure phenomena such as fracture and pin hole damage often occur in the operation of the gear rail of the shearer,and in order to improve the mechanical performance of shearer rack casting and ensure the smooth progress of coal mining,it is necessary to conduct in-depth analysis on the casting and forming process of the rack cutters to find the optimal casting process plan.Taking the five-pitch rack as the research object,and the ProCAST software is used to numerically simulate the casting process of the rack casting.Through the analysis of the simulation results of the solidification process and the isolated liquid phase area of the rack casting,the position of shrinkage cavity defects after the solidification of the gear rail casting is predicted.The causes and effect of defects in rack casting are analyzed by causal analytical method of TRIZ theory. The optimization scheme of rack casting process-inclined casting process is put forward by means of object-field model innovation solution tool: inclined pattern modeling,when pouring,the sand box and the straight runner are not inclined;or keep the cavity in sync with the sand box and straight runner during pouring. The results show that the defects of shrinkage cavity in rack casting have been greatly improved,but the first scheme one is not conducive to molding,and increases the height of the sand box;The second scheme increases the erosion of the pouring sprue by the pouring liquid can easily cause sand inclusion.Combining with the advantages of the two process schemes,the final optimization scheme is obtained: the pattern is placed horizontally,the mold cavity and the sand box are inclined synchronously during pouring to keep the vertical runner straight.ProCAST software is used to simulate the optimized inclined pouring process and the results show that this scheme can keep rack rail castings from increasing the temperature gradient during the solidification process,effectively promote sequential solidification of rack rail castings,and impro

关 键 词：采煤机齿轨铸件 TRIZ 倾斜浇注 工艺优化 铸造缺陷 

分 类 号：TD421[矿业工程—矿山机电]