铸件充型凝固过程数值模拟研究

概述了铸件充型及凝固过程数值模拟研究的最新进展。采用并行计算技术，对压铸充型模拟过程数值计算方法进行了改进。提出了用动态膨胀收缩累积法来预测球墨铸铁缩孔缺陷，在球铁件上进行了缩孔形成的模拟和工艺改进。采用的有限差分与有限元相结合的方法模拟铸件应力场。实现了有限差分温度载荷到有限元模型的自动转换与传递，并采用有限元法计算出铸件应力场。     

双辊薄带连铸凝固组织模拟微观模型的验证

以双辊薄带连续铸轧工艺凝固过程为基础,基于金属凝固的基本原理,并运用现代计算机仿真技术建立了双辊薄带连铸凝固过程的异质形核、修正的枝晶尖端生长动力学、柱状晶向等轴晶生长转变(CET)的解析模型以及基于元胞自动机(CA)的双辊薄带连续铸轧凝固组织的仿真模型,为双辊薄带连续铸轧凝固组织形成的仿真模拟奠定了基础,同时利用铝合金双辊薄带连续铸轧组织凝固过程验证了数学模拟的可行性。结果表明:可用建立的数学模型模拟预测铸轧工艺参数对双辊连续铸轧薄带凝固组织的影响。     

Cu-Cr合金快淬带的凝固数值模拟

建立了单辊快淬凝固过程的数值分析模型,将真空室、冷却辊和样品带作为一个整体换热系加以考虑,以厚度为60 μm的Cu-25%Cr合金快淬带为模拟对象,对其凝固过程进行了分析研究.由冷却曲线和温度场曲线模拟结果可知,带子的凝固时间为1.0×10-4s;单辊快淬的平均冷却速度在106K/s数量级,且凝固潜热的释放不会明显地引起冷却过程的温度回升;带子的凝固速度在0.010～0.394 m/s范围之内随凝固时间的延长逐渐由大变小.通过比较模拟结果和实验结果,且参考已有研究结论,证明了该模型的正确性,得到了Cu-Cr体系的一些凝固规律和凝固参数.     

Multiscale modelling and simulation of single crystal superalloy turbine blade casting during directional solidification process

As the key parts of an aero-engine,single crystal（SX）superalloy turbine blades have been the focus of much attention.However,casting defects often occur during the manufacturing process of the SX turbine blades.Modeling and simulation technology can help to optimize the manufacturing process of SX blades.Multiscale coupled models were proposed and used to simulate the physical phenomena occurring during the directional solidification（DS）process.Coupled with heat transfer（macroscale）and grain growth（meso-scale）,3D dendritic grain growth was calculated to show the competitive grain growth at micro-scale.SX grain selection behavior was studied by the simulation and experiments.The results show that the geometrical structure and technical parameters had strong influences on the grain selection effectiveness.Based on the coupled models,heat transfer,grain growth and microstructure evolution of a complex hollow SX blade were simulated.Both the simulated and experimental results show that the stray grain occurred at the platform of the SX blade when a constant withdrawal rate was used in manufacturing process.In order to avoid the formation of the stray crystal,the multi-scale coupled models and the withdrawal rate optimized technique were applied to the same SX turbine blade.The modeling results indicated that the optimized variable withdrawal rate can achieve SX blade castings with no stray grains,which was also proved by the experiments.     

Simulation and control model for interactions among process parameters of directional solidification continuous casting

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Construction and analysis of dynamic solidification curves for non-equilibrium solidification process in lost-foam casting hypoeutectic gray cast iron

Most lost-foam casting processes involve non-equilibrium solidification dominated by kinetic factors, while construction of a common dynamic solidification curve is based on pure thermodynamics, not applicable for analyses and research of non-equilibrium macro-solidification processes, and the construction mode can not be applied to nonequilibrium solidification process. In this study, the construction of the dynamic solidification curve (DSC) for the nonequilibrium macro-solidification process included: a modified method to determine the start temperature of primary austenite precipitation (TAL) and the start temperature of eutectic solidification (TES); double curves method to determine the temperature of the dendrite coherency point of primary austenite (TAC) and the temperature of eutectic cells collision point (TEC); the "technical solidus" method to determine the end temperature of eutectic reaction (TEN). For this purpose,a comparative testing of the non-equilibrium solidification temperature fields in lost-foam casting and green sand mold casting hypoeutectic gray iron was carried out. The thermal analysis results were used to construct the DSCs of both these casting methods under non-equilibrium solidification conditions. The results show that the transformation rate of non-equilibrium solidification in hypoeutectic gray cast iron is greater than that of equilibrium solidification. The eutectic solidification region presents a typical mushy solidification mode. The results also indicate that the primary austenite precipitation zone of lost-foam casting is slightly larger than that of green sand casting. At the same time, the solid fraction (fs) of the dendrite coherency points in lost-foam casting is greater than that in the green sand casting.Therefore, from these two points, lost-foam casting is more preferable for reduction of shrinkage and mechanical burntin sand tendency of the hypoeutectic gray cast iron. Due to the fact that the solidification process (from the surface to center) at primary austenite growth area in the lost-foam cylinder sample lags behind that in the green sand casting,the mushy solidification tendency of lost-foam casting is greater and the solidification time is longer.     

Numerical simulation of dendrite growth in Ni-based superalloy casting during directional solidification process

An understanding of dendrite growth is required in order to improve the properties of castings. For this reason, cellular automaton?finite difference (CA?FD) method was used to investigate the dendrite growth during directional solidification (DS) process. The solute diffusion model combined with macro temperature field model was established for predicting the dendrite growth behavior. Model validation was performed by the DS experiment, and the cooling curves and grain structures obtained by the experiment presented a reasonable agreement with the simulation results. The competitive growth of dendrites was also simulated by the proposed model, and the competitive behavior of dendrites with different misalignment angles was also discussed in detail. Subsequently, 3D dendrites growth was also investigated by experiment and simulation, and both were in good accordance. The influence on dendrites growth of initial nucleus was investigated by three simulation cases, and the results showed that the initial nuclei just had an effect on the initial growth stage of columnar dendrites, but had little influence on the final dendritic morphology and the primary dendrite arm spacing.     

Numerical simulation of solidification morphologies of Cu-0.6Cr casting alloy using modified cellular automaton model

The purpose of this study is to predict the morphologies in the solidification process for Cu-0.6Cr (mass fraction, %) alloy by vacuum continuous casting (VCC) and verify its accuracy by the observed experimental results. In numerical simulation aspect, finite difference (FD) method and modified cellular automaton (MCA) model were used to simulate the macro-temperature field, micro-concentration field, nucleation and grain growth of Cu-0.6Cr alloy using real data from actual casting operations. From the observed casting experiment, the preliminary grain morphologies are the directional columnar grains by the VCC process. The solidification morphologies by MCAFD model are in agreement with the result of actual casting experiment well.     

Numerical simulation of mold-temperature-control solidification

A finite element method（FEM） for the numerical simulation of the columnar part of the mould-temperature-control solidification（MTCS） process was presented. The latent heat was taken into account and 3D transient heat transfer analysis was carried out by using the developed FEM software. The relative errors between the numerical and experimental data are less than 6%. Three MTCS cases were computed with this method. The first case only opens the cooling channels in the bottom of the mold. The second case individually controls the separate 7 groups of cooling channels by giving 7 control points. When the temperature of a control point reaches the preset value of 400℃, the corresponding channel will be opened. The third case opens all the cooling channels at the same time. The results indicate that in the second case, the solid-liquid interface keeps near-planar. The growth velocity of the solid-liquid interface is 0.3-0.4 mm/s, which is greater than 0.1-0.3 mm/s of the first case, performing better than the others. Thus the forming quality and efficiency part interior can be improved by mold-temperature-control and the numerical model is validated. The numerical simulation of MTCS can provide an available tool for the advanced investigation on the defect improvement and the crystal＇s quality.     

大方坯连铸在线凝固传热模型的开发与应用

作为大方坯动态轻压下技术的核心模型,在线凝固传热模型为动态二冷控制模型和动态轻压下模型提供可靠而准确过程跟踪数据,为动态轻压下技术的有效实施提供保障。结合攀钢2号国产化大方坯铸机上建立的在线凝固传热模型,在此基础上进行了现场实际测温检验和应用,结果表明实测与计算的偏差小于1%,说明计算结果真实可靠,可满足在线计算要求。     

铝双辊连续铸轧凝固微观组织的数值模拟(英文)

在研究双辊连铸纯铝薄带凝固过程的基础上,基于金属凝固的基本原理,并运用现代计算机仿真技术建立双辊连续铸轧纯铝薄带凝固的异质形核,枝晶尖端的生长动力学(KGT),柱状晶向等轴晶生长的转变(CET)的解析模型;建立基于元胞自动机(CA)的双辊连铸纯铝薄带凝固组织的仿真模型,为双辊连铸薄带凝固组织的仿真模拟奠定基础,从而为双辊薄带连铸工艺提供一定的理论指导。同时,利用双辊薄带连续铸轧纯铝凝固微观组织过程验证数学模拟的可行性。     

Parallel algorithm of solidification process simulation for large-sized system of liquid metal atoms

1　INTRODUCTIONItiswellknownthatinthestudyofmicrostruc turesofmaterials ,sometimesitisdifficulttogetthedesiredresultsbecauseofthelimitofexperimentcon ditions .Forexample ,theX raydiffractioncannotbeusedtoshowtherealmicrostructuresofliquidoramorphousmetalswithintheirshort rangeorder .Duringtherapidcoolingprocessesfromliquidtoglassmetals,itisalsodifficulttoobservethetransientchangeoftheirmicrostructuresbyinstruments ,andsoon .Withthedevelopmentofcomputerscienceandtechnology ,however ,thoser…     

相场法凝固组织模拟的研究进展

阐述了相场法是一种用于模拟凝固微观组织的有效方法 ,是目前国内外的研究热点 ;论述了相场法模拟凝固微观组织的原理和国内外的研究现状 ,并指出进一步研究的方向。     

激光熔凝的数值模拟及其在激光定向凝固中的应用

建立了一套激光熔凝的数学模型和计算方法 ,给出了两种条件下熔池深度与扫描速度的关系曲线。计算结果与实验值吻合良好 ,验证了模型的有效性。根据计算分析了激光工艺参数与激光定向凝固组织的关系。据此通过工艺参数的匹配 ,在熔池顶部得到了与扫描方向完全一致的凝固组织     

Effect of vacuum on solidification process and microstructure of LFC magnesium alloy

Lost foam casting （LFC） is regarded as a cost-effective, environment-friendly vital option to the conventional casting process for production of near-net shape castings with high quality. Effect of vacuum on the solidification process and microstructure of LFC magnesium alloy were explored. The results indicate that vacuum plays a very important role in the heat transfer during mould filling and solidification periods, it increases the cooling rate of the filling melt, but greatly decreases the cooling rate of the casting during solidification period, and the solidification time of the casting is greater than that without vacuum. The microstructure of LFC magnesium alloy is rather coarse. Compared with that without vacuum, the microstructure of the LFC magnesium alloy under vacuum is more refined and has less precipitated β-phase, which is formed at the grain boundry and around the Al-Mn compound particle.     

低压铸造充型与凝固过程数值模拟

在根据金属低压铸造充型特点建立模型的基础上,利用有限元软件ANSYS成功地对某盘体铸件低压铸造充型过程的流场和温度场进行了模拟,并将模拟结果与实测结果进行比较,结果表明:计算机模拟结果与实验结果相符,实现了对铸件缺陷可能产生部位的预测和工艺参数优化。     

双辊薄带不锈钢铸轧过程数值模拟

采用有限元法模拟了双辊铸轧不锈钢过程的流热耦合问题;分析了铸轧速度对熔池内流场、温度场的影响以及流场与温度场之间的相互影响;通过熔池内温度场及温度梯度分析了熔池内凝固的发展及其对热流密度变化的影响。此模拟结果可以为控制铸轧过程的稳定提供有效的数据。     

液态金属快速凝固过程的PFM模型

近年来发展起来的PFM模型根据"溶质捕捉"和"溶质牵引"两种机制对金属及合金快速凝固过程进行数学描述及模拟, 较好地反映了金属凝固的物理本质. 介绍了PFM模型发展过程、研究现状及理论模型, 并对发展前景进行了展望.     

Development of thermal simulation system for heavy section ductile iron solidification

A new reliable thermal simulation system for studying solidification of heavy section ductile iron has been developed using computer feedback control and artificial intelligent methods. Results of idle test indicate that the temperature in the system responses exactly to the inputted control data and the temperature control error is less than ± 0.5 %. It is convenient to simulate solidification of heavy section ductile iron using this new system. Results of thermal simulation experiments show that the differences in nodularity and number of graphite nodule per unit area in the thermal simulation specimen and the actual heavy section block is less than 5 % and 10 %, respectively.