基于华铸CAE的铸造充型过程卷气缺陷定量预测研究  

Quantitative Prediction of Air Entrainment Defects in Casting Filling Process Based on InteCAST

作　　者：宋迎晨 计效园[1] 沈旭[1] 李文[1] 周建新[1] 殷亚军[1] SONG Yingchen;JI Xiaoyuan;SHEN Xu;LI Wen;ZHOU Jianxin;YIN Yajun(State Key Laboratory of Materials Processing and Die&Mould Technology,Huazhong University of Science and Technology,Wuhan 430074,China)

机构地区：[1]华中科技大学材料成形与模具技术全国重点实验室,武汉430074

出　　处：《精密成形工程》2024年第3期86-95,共10页Journal of Netshape Forming Engineering

基　　金：国家重点研发计划(2022YFB3706800)

摘　　要：目的针对目前单向流数值模拟软件无法模拟卷入金属液中的气体及其演变情况的问题,开展铸造充型过程卷气缺陷定量预测研究,开发基于华铸CAE的卷气定量预测系统,深入理解铸造卷气缺陷的形成原理与运动机理,准确预测金属充型过程中的卷气量和卷气造成的气孔缺陷,为生产实践提供指导。方法提出了一种金属充型过程卷入气体搜寻与追踪算法,将卷入金属液中未经考虑的气体进行保留,从而修正单向流系统,并基于此开发了卷气定量预测系统,并对该系统进行了验证。结果应用该系统后,原本未经考虑而消失的孤立气泡被保留下来以便进行后续计算,对液体体积进行了再分配,保证修改前后液体体积守恒,并修正了金属液速度,实现了卷气定量预测系统的基本功能。结论开发的卷气定量预测系统能够考虑到卷入金属液中的气体,并对气体做出定量预测,实现金属充型过程中气孔缺陷的定量预测,对生产实践中的工艺优化有一定的指导作用。The work aims to address the current limitation in numerical simulation software for unaccounted air entrainment and its evolution in molten metal,specifically focusing on the quantitative prediction of air entrainment defects during the cast-ing filling process and develop a quantitative prediction system for air entrainment based on InteCAST to gain a deep under-standing of the formation principles and motion mechanics of casting air entrainment defects,thus accurately predicting the volume of entrained air and the porosity defects caused by air entrainment during the metal filling process and providing guid-ance for practical production.An algorithm for searching and tracking entrained air in the metal filling process was proposed to retain the air that was previously overlooked in unidirectional flow simulations,thereby correcting the unidirectional flow sys-tem.Based on this,a quantitative prediction system of air entrainment was developed and validated.After the application of this system,isolated air bubbles that were initially neglected were retained for subsequent calculations.The liquid volume was redis-tributed,ensuring volume conservation before and after the modification,and the metal liquid velocity was corrected,achieving the basic functionality of the air entrainment quantitative prediction system.The developed air entrainment quantitative predic-tion system takes into account the air entrained in the molten metal,providing a quantitative prediction of entrained air and ena-bling the quantitative prediction of porosity defects during the metal filling process.This system offers guidance for process op-timization in practical production.

关 键 词：铸造 卷气缺陷 数值模拟 充型过程 定量预测 

分 类 号：TG21[金属学及工艺—铸造]