基于ProCAST的ZL114A尾段壳体凝固成形数值模拟与工艺优化

目的 针对ZL114A尾段壳体研制需求，利用低压充型液态成形工艺与数值仿真计算，预测疏松缺陷分布位置及严重程度，通过改进工艺来减少疏松缺陷，进而提高生产合格率。方法 基于ProCAST软件对ZL114A尾段壳体低压充型凝固过程进行仿真计算，分析充型凝固过程中的流动场与温度场分布、充型时间、流动长度与凝固时间，预测疏松缺陷分布位置及严重程度，结合枝晶相干点双电偶热分析法测试结果，对低压充型工艺进行设计优化。结果 由尾段壳体凝固疏松缺陷的仿真计算结果与枝晶相干点温度测试结果可知，低压充型增压速度得到提高，保压时间有所延长，对安装凸台冷铁材质与厚度进行设计优化后，疏松缺陷得到显著改善。结论 通过数值仿真计算指导了铸造工艺设计，制备得到了满足技术指标要求的ZL114A尾段壳体。

Numerical Simulation and Forming Optimization of ZL114A Tail Section Shell Solidification Process Based on ProCAST

The work aims to use numerical simulation analysis in conjunction with low-pressure filling process to forecast the micro-shrinkage distribution and severity of the ZL114A tail section shell according to the development needs, reducing the micro-shrinkage defects and improving the production conformity. The low-pressure filling and solidification process of the ZL114A tail section shell was simulated by ProCAST software to analyze the flow field and temperature field distribution, filling time, flow length and solidification time and predict the distribution location and severity of micro-shrinkage. Combined with the dendritic coherent point double-eletric-couple thermoanalysis test results, the design of filling process was optimized. Based on the simulation calculation of solidification shrinkage defects and the dendrite coherent point temperature test results, the pressurizing speed was improved and the pressure holding time was extended. After the design optimization of the material and thickness of the chill, a significant reduction in severity of micro-shrinkage was observed. The ZL114A tail section shell in conformity with technical standards is prepared based on the results of numerical simulation computation for guiding the solidification process design.