ZG20SiMn铸钢摇臂壳体铸造过程数值仿真及工艺优化  

Numerical simulation and process optimization of ZG20SiMn cast steel rocker arm shell casting process

作　　者：赵国超[1,2] 张一鸣 王慧 赵丽娟[1,2] 周国强 ZHAO Guochao;ZHANG Yiming;WANG Hui;ZHAO Lijuan;ZHOU Guoqiang(School of Mechanical Engineering,Liaoning Technical University,Fuxin 123000,China;Liaoning Provincial Key Laboratory of Large-Scale Mining Equipment,Fuxin 123000,China)

机构地区：[1]辽宁工程技术大学机械工程学院,辽宁阜新123000 [2]辽宁省大型工矿装备重点实验室,辽宁阜新123000

出　　处：《材料科学与工艺》2024年第3期78-86,共9页Materials Science and Technology

基　　金：国家自然科学基金资助项目(52204169,51674134);辽宁省教育厅项目(LJKQZ20222321).

摘　　要：摇臂壳体是采煤机的重要组成部件,具有多级壁厚、变截面等异形特征。为提高采煤机摇臂壳体铸造质量,解决因铸造工艺不成熟导致的缩松、缩孔等缺陷问题。以MG325型采煤机摇臂壳体为研究对象,设计顶注式和底注式两种铸造工艺方案,采用ProCAST软件探究不同浇注工艺方案下摇臂壳体铸件充型及凝固过程,分析铸件温度场、凝固场及缩松、缩孔铸造缺陷位置。基于Niyama判据和应力场分布对底注式铸造工艺方案进行优化。结果表明:优化后摇臂壳体铸件在凝固冷却过程中保持温度梯度递增,促进铸件实现顺序凝固,铸件缺陷率明显降低且充型效果更佳,缩孔体积仅占摇臂壳体体积的0.0049%,电机孔薄壁端面应力优化量为38.47%,输出端孔处应力优化量达到91.08%。本文研究成果为采煤机摇臂壳体的铸造工艺提供了理论基础和数据支撑。Rocker arm shell is an important component of shearer with multistage wall thickness,variable cross-section and other heterogeneous features.Aiming to improve the casting quality of shearer rocker arm shell and resolve defects such as shrinkage porosity and shrinkage cavity caused by immature casting processes,the rocker arm shell of MG325 shearer was taken as the research object.Two casting process schemes,top-injection and bottom-injection,were designed and ProCAST software was used to investigate the filling and solidification process of shearer rocker arm shell castings under different pouring schemes.Meanwhile,the temperature field and solidification field as well as the position of shrinkage porosity and shrinkage cavity defects were analyzed.Based on Niyama criterion and stress field distribution,the bottom-injection casting process was optimized.The results show that the shearer rocker arm shell castings in the solidification and cooling process maintain an incremental temperature gradient after optimization,effectively promoting the castings to achieve sequential solidification.The defect rate of rocker arm shell castings is significantly reduced and the filling effect is improved after optimization.The shrinkage hole volume only accounts for 0.0049%of the rocker arm shell volume.The stress optimization at the thin-wall end face of the motor hole is 38.47%,while the stress optimization at the output port reaches 91.08%.The research results provide a theoretical basis and data support for the casting technology of shearer rocker arm shell.

关 键 词：采煤机 摇臂壳体 铸造缺陷 工艺优化 残余应力 

分 类 号：TD421[矿业工程—矿山机电]