曳引轮铁型覆砂铸造过程温度场数值模拟与精度提升  

Numerical Simulation of Temperature Field and Precision Improvement in Sand-Lined Metal Mold Casting Process of Traction Wheel

作　　者：胡学帅 汪东红 吴文云[1] 朱国 夏小江 邱仲华 黄列群 疏达 HU Xue-shuai;WANG Dong-hong;WU Wen-yun;ZHU Guo;XIA Xiao-jiang;QIU Zhong-hua;HUANG Lie-qun;SHU Da(School of Materials Engineering,Shanghai University of Engineering Science,Shanghai 201620,China;School of Materials Science and Engineering,Shanghai Jiao Tong University,Shanghai Key Lab of Advanced High-Temperature Materials and Precision Forming,Shanghai 200240,China;Zhejiang Institute of Mechanical&Electrical Engineering Co.,Ltd.,Hangzhou 310051,Zhejiang,China;Huzhou Dingsheng Machinery Manufacturing Co.,Ltd.,Huzhou 313000,Zhejiang,China)

机构地区：[1]上海工程技术大学材料工程学院,上海201620 [2]上海交通大学材料科学与工程学院,上海市先进高温材料及其精密成形重点实验室,上海200240 [3]浙江省机电设计研究院有限公司,浙江杭州310051 [4]湖州鼎盛机械制造有限公司,浙江湖州313000

出　　处：《铸造》2023年第10期1260-1266,共7页Foundry

基　　金：国家重点研发计划(2020YFB1710100,2022YFB06800);国家自然科学基金(51821001,52074183,52090042);长寿命高温材料国家重点实验室开放基金(DECSKL202109);材料成形与模具技术国家重点实验室开放基金(P2021-006);浙江省重点研发计划(2021C01157,2022C01147)。

摘　　要：铁型覆砂铸造过程中工艺参数难控制、传热复杂,为了提升温度场数值模拟计算精度,提出“精确模型-精确工艺参数”的数值模拟前处理方法:根据本工艺特有的模型变厚度工艺设计,对铁型、覆砂层、铸件、浇注系统等进行精确几何建模,使用ProCAST数据库计算材料热物性参数,采用ProCAST的反算模块反向求解得到温度函数的界面换热系数,将随温度变化的参数代替恒定值参数作边界条件。本文以某型曳引轮为例,针对优化浇冒系统后仍存在的细微缺陷,使用上述精确前处理方法,铸件内部缩松、缩孔缺陷及孤立液相区消失,冒口处缩松缩孔体积减少5.2%,经实际生产验证模拟计算精度获得提高。In the process of sand-lined iron mold casting,the process parameters are difficult to control and the heat transfer is complex.In order to improve the accuracy of numerical simulation calculation of temperature field,a numerical simulation pretreatment method of“accurate model-accurate process parameters”is proposedaccording to the unique model thickening process design,accurate geometric modeling of iron mold,sand coated layer,castings,gating system and so on is carried out,and the thermal physical parameters of materials are calculated using ProCAST database.The interface heat transfer coefficient of the temperature function is obtained by using the inverse calculation module of ProCAST,and the parameters varying with temperature are used as boundary conditions to replace the constant boundary conditions.In this paper,taking a certain type of traction wheel as an example,aiming at the subtle defects that stllexist after optimizing the pouring system,using the above precise pretreatment method,the internal shrinkage defects,shrinkage cavity defects and isolated liquid phase area of the casting disappear,and the volume of shrinkage cavity at the riser is reduced by 5.2%.The simulation accuracy is improved after the actual production verification.

关 键 词：铁型覆砂 温度场模拟 工艺优化 界面换热系数 反算优化 

分 类 号：TG249[金属学及工艺—铸造]