钛合金异形薄壁壳体铸造工艺数值模拟及优化

为解决钛合金精密铸造产品合格率低、试验优化周期长的问题,以某钛合金异形薄壁件为研究对象,采用逆向工程手段优化浇注系统设计。结合ProCAST有限元分析软件确定铸件缺陷分布位置,依据铸件缩松分布情况对铸造方案进行迭代优化,解决铸件承力板区域缩孔问题。根据优化结果进行生产验证,结果表明,钛合金铸件采用真空熔模铸造方案,铸件上、下端分别设置3处浇/冒口时,模拟结果显示铸件凝固过程整体温度分布合理,铸件中的缩孔均被优化剔除。该工艺方案可行性高,试制件无损检测结果与数值模拟结果吻合度高,铸件成形质量、冶金质量均达到预期效果。

Numerical simulation and optimization of titanium alloy shaped thin-walled shell casting process

In order to solve the problem of low qualification rate and long test optimization period of titanium alloy precision casting products, a reverse engineering approach was adopted to optimize the design of pouring system for a titanium alloy shaped thin-walled part. The location of casting defects was determined using ProCAST finite element analysis software, the casting solution was iteratively optimized to avoid regional shrinkage in the casting bearing plate based on the distribution of casting shrinkage. Finally, production validation was carried out based on the optimization results. The results show that the overall temperature distribution during casting solidification process is reasonable and shrinkage holes in casting products are eliminated when three pouring/pouring ports are respectively set at the upper and lower ends of the casting products using vacuum investment for titanium alloy casting. This process scheme is highly feasible. When the above scheme is used, the non-destructive testing results of trial parts are in good agreement with the numerical simulation results, and the casting forming quality and metallurgical quality all achieved the expected results.