CAE技术在铸造模具工艺优化中的应用

采用华铸CAE软件对铝合金壳体铸件的金属型铸造过程进行了数值模拟，通过对几种铸造模具工艺方案的数值模拟和实验,优选出了一种最佳的铸造工艺用于生产，成功地消除了壳体铸件生产过程的缩孔、缩松缺陷。模拟结果与实际生产中的情况吻合较好。结果表明：CAE技术能为工艺方案的评价和改进提供科学的依据，能缩短新产品的开发周期，为企业带来了显著的经济效益。     

数值模拟在后桥壳体铸造工艺优化中的应用

采用三维造型软件对后桥壳体铸件进行造型,添加浇冒系统和铸型,用华铸CAE软件进行凝固过程的数值模拟,通过比较不同工艺条件下的凝固过程中的液相动态分布过程,预测了形成缩孔缺陷的不同倾向,并对比了不同工艺方案下铸件的缩孔分布及工艺出品率,对铸造工艺进行改进和优化,将改进后的铸造工艺应用于生产,既解决了铸件的铸造缺陷,又缩短了生产制造周期。     

球铁轮毂的凝固数值模拟及铸造工艺优化

采用华铸CAE软件,对客车的球墨铸铁轮毂铸件的凝固过程进行了数值模拟,根据对铸造工艺方案的凝固模拟和实验结果分析,获得了1种合适的铸造工艺用于轮毂铸件生产,有效地消除了轮毂生产过程的缩孔、缩松缺陷。     

基于铸造CAE的弹簧座铸件熔模铸造工艺研究

针对弹簧座铸件提出两种工艺方案,利用铸造CAE软件对铸件的凝固过程进行数值模拟,并将模拟结果对比分析,从中选出最优工艺方案.通过实际生产验证,确定改进工艺方案切实可行.结果表明,利用CAE软件,可以为优化浇注系统,制定最佳浇注工艺提供指导.     

两种国产铸造数值模拟软件的应用

为了比较两种国产铸造数值模拟软件,在新型车辆安装座的熔模铸造生产过程中,拟订了6种工艺方案,采用直觉式平台Pidex进行三维建模、华铸InteCast与浩宇HyCast进行数值模拟。对6种方案均进行试生产。对铸件进行外观检测与X射线检测,验证铸造CAE的模拟结果。综合比较结果证明,两种国产铸造数值模拟软件都能很好满足铸造生产需要。     

数值模拟在铸钢壳体铸件工艺优化中的应用

采用PRO/E三维造型软件对铸钢壳体铸件进行造型,添加浇冒系统,用华铸CAE软件进行凝固过程的数值模拟,通过比较不同工艺条件下的凝固过程中的液相动态分布过程,预测了形成缩孔（松）缺陷的不同倾向,并对比了不同工艺方案下铸件的缩孔（松）分布,对铸造工艺进行改进和优化,将改进后的铸造工艺应用于生产,既解决了铸件的铸造缺陷问题,又加快了工艺开发周期。     

薄壁铝合金壳体低压铸造工艺设计及模拟优化

对重要结构件薄壁铝合金壳体进行了低压铸造工艺设计,通过对充型流场、温度场以及缩孔、缩松的数值模拟预测,优化了该铸件的低压铸造工艺方案。模拟结果表明,采用导热更好的铜芯替换钢芯,能获得平稳的充型行为和均匀的温度场,预测的缩孔、缩松未出现在铸件上;优化后的薄壁铝合金壳体铸件的低压铸造工艺方案合理,可以有效地优化壳体温度场,降低铸件出现缩孔、缩松的几率,生产出了合格铸件。     

基于数值模拟的优质铝合金铸件工艺优化

采用数值模拟软件ProCAST模拟并优化了壳体铸件的铸造工艺,同时通过实际生产对比模拟结果。结果表明,模拟结果能较好地反映铸件铸造工艺实际情况,从而验证了ProCAST软件能为铸件铸造工艺优化设计提供技术支持。     

低压铸造盘形壳体铸件的工艺优化

结合铸件质量问题,基于铸造数值模拟技术,分析了低压铸造的充型凝固过程,预测了几种改进工艺方案后铸件中的缺陷分布;最终通过试制,确保了盘形壳体低压铸件质量,为该件的顺利生产奠定了基础.     

减速器壳体铸造工艺设计的探讨

介绍了湿型砂生产减速器壳体的铸造工艺设计,利用华铸CAE对初始工艺方案浇冒系统进行充型及凝固的模拟,发现差速锁热节位置存在缩松缺陷。根据缺陷形成原因的分析,对铸造工艺进行了优化。并经生产验证,优化后的铸造工艺能保证铸件内部致密,产品满足客户要求。     

薄板坯连铸结晶器内钢水凝固传热数值模拟

为研究薄板坯连铸高拉速下结晶器内坯壳生长过程,利用ANSYS有限元模拟软件,建立了CSP薄板坯连铸结晶器内钢水凝固传热数学模型,并通过实际测量得到的凝固坯壳厚度验证了模型的合理性。对结构用钢Q235B钢种,1 500 mm×60 mm规格在结晶器内凝固过程进行了模拟,研究了不同拉速、不同结晶器冷却水量对凝固的影响。研究结果表明,随着拉速降低,坯壳厚度增加;随着结晶器水量增大,坯壳厚度增加,模拟结果与实测结果相符合,为实际生产优化工艺参数提供了理论参考。     

型壳材料对高温合金叶片组织和性能的影响

采用数值模拟方法并结合试验,研究了型壳材料对高温合金叶片组织和性能的影响。结果表明,无陶瓷保温棉时,氧化铝型壳铸件的冷却速率大于莫来石型壳,氧化铝型壳铸件组织及性能较优;有陶瓷保温棉时,氧化铝型壳铸件叶根处冷却速率略低于莫来石型壳铸件,叶身处冷却速率高于莫来石型壳铸件,莫来石型壳铸件叶根处组织及性能比氧化铝型壳铸件略优,叶身组织及性能比氧化铝型壳铸件略差。有陶瓷保温棉时的铸件叶根组织数值模拟结果和试验结果符合。     

Numerical simulation and optimization of shell mould casting process for leaf spring bracket

Although the shell mould casting process has a wide range of application in many fields,the prediction of casting defects is still a problem.In the present work,a typical leaf spring bracket casting of ZG310-570 was fabricated by shell mold casting.The finite element model and ProCAST software were utilized for simulating the filling and solidification processes of the casting;and the formation mechanism of the gas pore,and shrinkage porosity defects were analyzed.The results indicate that the gas pore and shrinkage porosity defects are formed due to air entrapment,insufficient feeding and non-sequential solidification.Subsequently,through changing the position of risers,adding a connecting channel between the risers,and setting blind risers at the U-shaped brackets,an optimized gating and feeding system was established to improve the quality of the casting.After optimization,the gas pore and shrinkage porosity defects of the leaf spring bracket casting are effectively eliminated.The experiment results with the optimized casting process are in good agreement with the numerical simulation,which verifies the validity of the finite element model in the shell mould casting.     

重力铸造铝合金压壳的顶浇工艺实践

压壳的金属型顶浇工艺最主要的是解决落差冲击造成的乱流卷渣问题,以及指向性凝固问题。本文从浇铸落差与浇口大小对压壳渣孔的影响进行了计算分析,借助模流分析软件Anycasting对下模底部不同高度冷却柱的铝液充型进行了模拟,并且将模拟与计算分析结果与生产实践验证。结果表明,解决与改善了常见的渣孔问题。     

基于数值模拟的铝合金壳体浇注系统优化设计

针对铝合金壳体的结构特点,应用UG软件设计了浇注系统方案一,并应用铸造分析软件Any casting对熔融铝合金液充型和凝固过程进行了模拟,通过模拟结果判断方案一的优缺点,设计了优化的浇注系统方案二和方案三,通过比较得到了优化的浇注系统进料位置和进料方式,对成型零件的质量有很重要影响。     

Research progress on refractory composition and deformability of shell molds for TiAl alloy castings

At present, most TiAl components are produced by an investment casting process. Environmental and economic pressures have, however, resulted in a need for the industry to improve the current casting quality, reduce manufacturing costs and explore new markets for the process. Currently, the main problems for investment casting of TiAl alloys are cracks, porosities, and surface defects. To solve these problems, many studies have been conducted around the world, and it is found that casting defects can be reduced by improving composition and properties of the shell molds. It is important to make a summary for the related research progress for quality improvement of TiAl castings. So, the development on refractory composition of shell molds for TiAl alloy investment castings was reviewed, and research progress on deformability of shell mold for TiAl alloy castings both at home and abroad in recent years was introduced. The existing methods for deformability characterization and methods for improving the deformability of shell molds were summarized and discussed. The updated advancement in numerical simulation of TiAl alloy investment casting was presented, showing the necessity for considering the deformability of shell mold during simulation. Finally, possible research points for future studies on deformability of shell mold for TiAl alloy investment casting were proposed.     

基于数值模拟的防喷器壳体铸造工艺优化

根据防喷器壳体结构特点及技术要求进行了工艺性分析并拟订了工艺方案.基于数值模拟技术对铸件的热节部位、冒口的补缩能力等进行了数值模拟,根据模拟结果探明了工艺热节和铸造缺陷产生原因,并通过反复修改工艺参数对工艺进行了改进,得到了较为理想的工艺方案.这对缩短试验周期,减小同类型产品冒口尺寸,提高工艺出品率,节省原材料等有着重要的意义.     

拉速液位与结晶器出钢温度的关系研究

结晶器液位和铸坯拉速可直接影响结晶器内钢液温度.本文基于数值模拟和钢液凝固机理,建立起结晶器内钢液液位和铸坯拉速对其出钢口处钢液截面平均温度和坯壳温度的制约关系.仿真结果表明,所建立的关系模型能够反映结晶器出钢口处坯壳表面温度的动态变化,及间接地预知坯壳厚度目的.     

Crack prediction using nonlinear finite element analysis during pattern removal in investment casting process

A three-dimensional transient thermo-mechanical coupled nonlinear finite element model was developed to predict the possible crack formation of ceramic shell during rigid polymer pattern removal in the investment casting process. A smeared crack model was used to describe the response of the ceramic shell when crack initiates. A foam degradation model was implemented to account for the loss of mechanical properties of the foam during firing process. The effects of firing method, pattern type and complex geometry were investigated. The simulation results were validated with experimental findings. The developed model not only serves as a useful tool for designing foam patterns but also can be used for optimizing firing process parameters in investment casting process.