CN107014973B - A kind of gravitational casting shrinkage cavity defect detection method based on dynamic pressure - Google Patents
A kind of gravitational casting shrinkage cavity defect detection method based on dynamic pressure Download PDFInfo
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Abstract
The invention belongs to the shrinkage prediction correlative technology field in gravitational casting process of setting, the gravitational casting shrinkage cavity defect prediction technique based on dynamic pressure that it discloses a kind of comprising following steps: (1) initialize running gate system；(2) derive that critical pressure intensity values using the boundary criterion as isolated liquid phase area searching, and then search out the distribution of the isolated liquid phase region at certain moment；Liquid phase region is isolated if it exists, then turns to step 3；Otherwise terminate；(3) successively judge whether isolated liquid phase region divides and bury in oblivion, if division, turns to step 4, if do not divided, and then judge whether isolated liquid phase region buries in oblivion, if do not buried in oblivion, turn to step 4, otherwise turn to step 5；(4) it after the distribution of the shrinkage cavity at search each isolated liquid phase region moment, calculates and divides equally and be superimposed the contractions increment of each isolated liquid phase region to searching on obtained grid；(5) it is recycled after updating the liquid fraction of all areas, until all isolated liquid phase regions disappear.
Description
Technical field
The invention belongs to the shrinkage prediction correlative technology fields in gravitational casting process of setting, more particularly, to one kind
Gravitational casting shrinkage cavity defect prediction technique based on dynamic pressure.
Background technique
Alloy density causes alloy volume in process of setting slightly to reduce with temperature change, and the feeding of molten metal causes portion
Subregion lacks external metallization liquid supplement and generates shrinkage cavity or shrinkage defect.For casting, suitable casting system is designed
System and riser reduce or avoid the shrinkage porosity defect of contraction cavity on casting ontology most important completely.Before process of setting starts, liquid
Body Feeding channel is more unimpeded；After process of setting starts, solid forming core particle, solid shape are gradually formed in metal liquid
Nuclear particle is stepped up viscosity, and the flow velocity of the feeding in semi-solid-state metal liquid is caused to gradually reduce, final to generate concentration
Shrinkage cavity, and the formation mechenism for studying shrink defects in casting generallys use the method that experiment is combined with theory.However, gravity is cast
The formation and growth for making shrinkage cavity in process of setting are affected by many factors, extraneous other than alloy intrinsic characteristic and parameter
The influence of factor is also most important, and wherein the influence of gravitational field and atmospheric pressure not can not be ignored.
Currently, relevant technical staff in the field has done some researchs, such as simplified model, most of algorithms with
Simple critical solid rate, as the method for judging multiple isolated liquid phase regions, and for shrinkage cavity each step distribution, then
Directly assume that shrinkage cavity can be distributed the top in form, leads to the search criteria and isolated liquid phase region internal shrinkage of isolated liquid phase region
The regularity of distribution is not perfect, affects precision of prediction.Correspondingly, there is develop a kind of higher gravitational casting contracting of precision for this field
The technical need of hole defect prediction technique.
Summary of the invention
Aiming at the above defects or improvement requirements of the prior art, the gravity casting based on power pressure that the present invention provides a kind of
The characteristics of making shrinkage cavity defect prediction technique, being based on gravitational casting shrinkage cavity, is set for gravitational casting shrinkage prediction method
Meter.The gravitational casting shrinkage cavity defect prediction technique can within the limited time, the threedimensional model, corresponding according to running gate system
Material property parameter and casting technological parameter relatively accurately simulate the position of shrinkage cavity, size and pattern under this casting technique,
There is good reference value to actual production.
To achieve the above object, the present invention provides a kind of gravitational casting shrinkage cavity defect prediction side based on dynamic pressure
Method comprising following steps:
(1) threedimensional model for constructing running gate system initializes the running gate system in the solidification incipient stage, this
When, entire molten metal region is one (father) isolated liquid phase region；
(2) it is derived by the equation of motion of Darcy's law and is faced needed for the feeding resistance overcome between each isolated liquid phase region
Boundary's pressure values are searched out using the critical pressure intensity values as the boundary criterion of isolated liquid phase area searching according to the boundary criterion
The distribution of the isolated liquid phase region at certain moment；If being carved with isolated liquid phase region at this time to exist, step 3 is turned to；Otherwise terminate；
(3) successively judge whether isolated liquid phase region divides and bury in oblivion, if division, turns to step 4, if isolated liquid
Phase region does not divide, then and then judges whether isolated liquid phase region buries in oblivion, if do not buried in oblivion, turns to step 4, otherwise turns to step
Five；
(4) each isolated liquid phase region is marked, the shrinkage cavity based on boundary criterion search each isolated liquid phase region moment
Distribution after, calculate the contraction increment of each isolated liquid phase region, simultaneously scan for the smallest all nets of pressure in each isolated liquid phase region
The contraction increment of each isolated liquid phase region is divided equally and is added on all grids that search obtains by lattice；
(5) liquid fraction is calculated according to equilibrium equation " solid rate+liquid fraction+shrinkage cavity score=100% ", while updated all
After the liquid fraction in region, increases time step to subsequent time and go to step 2 and recycled, until all isolated liquid phases
Qu Jun disappears, to obtain final shrinkage cavity distribution.
Further, the Rule of judgment whether critical pumping rate is isolated liquid phase region connection.
Further, it will solidify what mushy zone was handled as porous media when deriving the boundary criterion, wherein coagulating
Gu the feeding speed of the molten metal of mushy zone is associated with the variation in temperature field；When searching for the distribution of isolated liquid phase region, it is assumed that
Each moment fluid is in quasistatic process, then fluid meets minimum potential energy principal in gravitational field.
Further, the critical pressure is calculated by following formula and is obtained:
Wherein, fsFor solid rate, flFor liquid fraction, CTFor Models For Secondary Dendrite Arm spread ratio, ρsFor solid Density, ρlFor liquid phase
Density, μ are viscosity, dx be space lattice step-length,It is temperature gradient for change of temperature field rate, G.
Further, the distribution of shrinkage cavity is divided into three kinds of situations: not depositing if 1. isolating liquid phase region inner metal liquid with surrounding air
In contact surface, then shrinkage cavity will be distributed over the isolated the smallest position of liquid phase region inner metal liquid pressure；2. such as gold in isolated liquid phase region
Belonging to liquid, there are contact surfaces with surrounding air, and the minimum pressure in molten metal is greater than 0, then shrinkage cavity will be distributed over the isolated liquid phase region
On the contact surface of inner metal liquid and air；3. if isolated liquid phase region inner metal liquid and surrounding air are there are contact surface, and molten metal
Interior minimum pressure is equal to 0, then shrinkage cavity will be distributed in simultaneously the contact surface and pressure of the isolated liquid phase region inner metal liquid and air most
Small position.
Further, the contraction increment for isolating liquid phase region is calculated by following formula:
Wherein, Δ Ω is the volume of single grid, Δ VlFor the variable quantity of liquid volume in grid single in t to t+ Δ t,
ΔfsTo solidify percentage, ρsFor solid Density, ρlFor density of liquid phase.
In general, through the invention it is contemplated above technical scheme is compared with the prior art, base provided by the invention
In the gravitational casting shrinkage cavity defect prediction technique of dynamic pressure, the equation of motion according to Darcy's law, which is derived, overcomes each isolate
Critical pressure intensity values needed for feeding resistance between liquid phase region are sentenced using the boundary of the critical pressure intensity values as isolated liquid phase area searching
According to, and then the distribution of isolated liquid phase region is found according to the boundary criterion, and search out the shrinkage cavity distribution of each isolated liquid phase region
After re-start distribution and circulation, until all isolated liquid phase region disappears, to obtain final shrinkage cavity distribution, realizing is having
In the time of limit, according to threedimensional model, corresponding material property parameter and the casting technological parameter of running gate system, relatively accurately
The position of shrinkage cavity, size and pattern under this casting technique are simulated, there is good reference value to actual production.
Detailed description of the invention
Fig. 1 is the gravitational casting shrinkage cavity defect prediction technique based on dynamic pressure that better embodiment of the present invention provides
Flow chart.
Fig. 2 is contracted under the gravitational casting that the gravitational casting shrinkage cavity defect prediction technique based on dynamic pressure in Fig. 1 is related to
The schematic diagram of three kinds of distributions in hole.
Fig. 3 is that the isolated liquid phase region that the gravitational casting shrinkage cavity defect prediction technique based on dynamic pressure in Fig. 1 is related to is drilled
The schematic diagram of three kinds of states of change process.
Specific embodiment
In order to make the objectives, technical solutions, and advantages of the present invention clearer, with reference to the accompanying drawings and embodiments, right
The present invention is further elaborated.It should be appreciated that the specific embodiments described herein are merely illustrative of the present invention, and
It is not used in the restriction present invention.As long as in addition, technical characteristic involved in the various embodiments of the present invention described below
Not constituting a conflict with each other can be combined with each other.
It please refers to Fig.1 to Fig.3, the gravitational casting shrinkage cavity defect based on dynamic pressure that better embodiment of the present invention provides
Prediction technique, the gravitational casting shrinkage cavity defect prediction technique mainly comprise the steps that
Step 1 constructs the threedimensional model of running gate system, in the solidification incipient stage, the running gate system is carried out initial
Change.At this point, when entire molten metal region is one (father) isolated liquid phase region, i.e. t=0, only one isolated liquid phase region.
Step 2 is derived by the equation of motion of Darcy's law needed for the feeding resistance overcome between each isolated liquid phase region
Critical pressure intensity values searched using the critical pressure intensity values as the boundary criterion of isolated liquid phase area searching according to the boundary criterion
The distribution of isolated liquid phase region when rope goes out t=t+ δ t；If being carved with isolated liquid phase region at this time to exist, step 3 is turned to；Otherwise it ties
Beam.In present embodiment, solidification mushy zone is thought of as porous media when deriving the boundary criterion and is handled, wherein solidifying
The feeding speed of the molten metal of mushy zone is associated with the variation in temperature field；When searching for the distribution of isolated liquid phase region, it is assumed that every
One moment fluid is in quasistatic process, then fluid meets minimum potential energy principal in gravitational field；Pressure is distributed in molten metal
And dynamic equilibrium should be met with metal hydraulic strongly consistent during actual casting.
Specifically, the temperature field that this moment is calculated using Fourier equation, initialize the solid rate in each region, liquid fraction and
Shrinkage cavity score calculates the dynamic pressure distribution in molten metal at this time.The boundary criterion includes solid rate fs, liquid fraction fl、
Models For Secondary Dendrite Arm spread ratio CT, solid Density ρs, density of liquid phase ρl, viscosity μ, space lattice step-length dx, change of temperature field rate
The parameters such as temperature gradient G, the critical pressure are calculated by following formula and are obtained:
Meanwhile according to formula P0-ρgzA+ C calculates the actual pressure value in molten metal at each point, and wherein C is constant, ρ
For the density of molten metal.C meets the following conditions: if 1. the isolated liquid phase region and surrounding air have a contact surface, on contact surface
Actual pressure Patm=-ρ gz1+ C, wherein ρ is the density of molten metal, z1For certain point on contact surface, PatmFor surrounding air pressure
By force.2. if contact surface is not present in the isolated liquid phase region and surrounding air, in isolated liquid phase region at the smallest position of pressure, pressure
Strong is 0, i.e. C meets 0=- ρ gz2+C.Constant C may be different between each isolated liquid phase region, and inside each isolated liquid phase region
Then remain unchanged.In present embodiment, critical pressure criterion is used to isolate the crucial Rule of judgment whether connection of liquid phase region；Foundation
The boundary criterion searches out size, position and the shape of all isolated liquid phase regions.
Step 3, successively judges whether isolated liquid phase region divides and bury in oblivion, if division, turns to step 4, if lonely
Vertical liquid phase region does not divide, then and then judges whether isolated liquid phase region buries in oblivion, if do not buried in oblivion, turns to step 4, otherwise turns to
Step 5.Specifically, after obtaining all isolated liquid phase regions, liquid phase region is isolated to all sons one by one and father isolates liquid phase region and carries out
Judgement judges that father isolates the evolving state (divide, keep, burying in oblivion) of liquid phase region.
Since the change of temperature field of molten metal in process of setting is unidirectional cooling direction, isolated liquid phase region centainly subtracts
It is small, and in the evolution process of isolated liquid phase region, can be there are three types of possible state: 1. it is lonely to be split into multiple sons for the isolated liquid phase region of father
Vertical liquid phase region；It is not divided 2. father isolates liquid phase region, becomes the lesser isolated liquid phase region of son；Disappear 3. father buries in oblivion isolated liquid phase region
It loses, wherein isolated liquid phase region, which disappears, can then leave a shrinkage cavity, it is final after disappearance is buried in oblivion in all isolated liquid phase regions
Shrinkage cavity distribution.Father isolates liquid phase region due to area reduction, it includes several regions for being not belonging to the isolated liquid phase region of son in metal
In the distribution search for the shrinkage cavity that liquid solidification generates, the 2. plant state and the 3. kind state be relatively easy to, 2. plant state for the, father
The shrinkage cavity that all molten metal solidifications generate in isolated liquid phase region can stay in the isolated liquid phase region of its son.Shape is 3. planted for
State, father, which isolates the shrinkage cavity that molten metal solidification all in liquid phase region generates, can stay in the region and form an independent contracting
Hole.And state is 1. planted for the, due to the presence of the isolated liquid phase regions of multiple sons, father, which isolates in liquid phase region, is not belonging to the isolated liquid phase of son
The region in area isolates the distance of liquid phase region according to it with each height, is integrated into and isolates in liquid phase region apart from nearest son.
Step 4 marks each isolated liquid phase region, each isolates liquid phase region in t=t+ δ t based on boundary criterion search
When shrinkage cavity distribution after, calculate the contraction increment of each isolated liquid phase region, it is minimum to simultaneously scan for pressure in each isolated liquid phase region
All grids, the contraction increment of each isolated liquid phase region is divided equally and is added on all grids searched.
Specifically, in gravity casting process, the regularity of distribution of shrinkage cavity is divided into three kinds of situations: if 1. gold in certain isolated liquid phase region
Belong to liquid and surrounding air and contact surface is not present, then precedence partition is isolated the liquid phase region the smallest position of inner metal liquid pressure at this by shrinkage cavity
It sets；2. as there are contact surfaces with surrounding air for isolated liquid phase region inner metal liquid, and minimum pressure is greater than 0 in molten metal, then shrinkage cavity
By precedence partition on the contact surface for isolating liquid phase region inner metal liquid and air；3. such as isolated liquid phase region inner metal liquid and environment
There are contact surfaces for air, and minimum pressure is equal to 0 in molten metal, then shrinkage cavity will be distributed in the isolated liquid phase region inner metal liquid simultaneously
With the smallest position of contact surface and pressure of air.If certain father isolates liquid phase region s.m.p and isolates liquid phase region, show that the father is isolated
Disappearance is buried in oblivion in liquid phase region, in shrinkage cavity and dilatation and its original shrinkage cavity volume superposition after become the regional area most
Final minification pore size distribution.
Meanwhile the shrinkage cavity dilatation (shrinking increment) that each height for calculating this moment isolates in liquid phase regionThe volume delta of each single grid in zonule as in the isolated liquid phase region
Ω internal cause solidifies percent delta fsWith solid-liquid density difference ρsWith ρlThe sum of generated shrinkage cavity volume, wherein Δ Ω is single grid
Volume, Δ VlFor the variable quantity of liquid volume in grid single in t to t+ Δ t.For newly-increased shrinkage cavity volume has been calculated
The son of score isolates liquid phase region, traverses whether it contacts with surrounding air one by one, if 1. not contacting with air environment, searches for it
The quantity and distribution for the position that internal pressure is 0, newly-increased shrinkage cavity volume is divided equally and is superimposed by the quantity of the position for the condition that meets
Onto these positions；2. searching for position (if present) that its interior pressure is 0 and molten metal and air if contacting with air environment
The quantity and distribution of contact surface position are divided equally newly-increased shrinkage cavity volume and these positions that are added to by the quantity of the position for the condition that meets
It sets.
Step 5 calculates liquid fraction according to equilibrium equation " solid rate+liquid fraction+shrinkage cavity score=100% ", updates simultaneously
Step 2 is gone to after the liquid fraction of all areas to be recycled, it is final to obtain until all isolated liquid phase regions disappear
Shrinkage cavity distribution.Specifically, the solid rate of all areas is determined by temperature place, and shrinkage cavity score is updated by shrinkage cavity assigning process,
After liquid fraction can be calculated according to the equilibrium equation, the liquid fraction of all areas is updated；Later, increase time step under
It at one moment, repeats the above steps, until disappearance is buried in oblivion in all isolated liquid phase regions, obtains final shrinkage cavity distribution, exit and follow
Ring.
Gravitational casting shrinkage cavity defect prediction technique provided by the invention based on dynamic pressure, the fortune according to Darcy's law
Critical pressure intensity values needed for dynamic equation inference goes out the feeding resistance overcome between each isolated liquid phase region, to be searched as isolated liquid phase region
The boundary criterion of rope, and then the distribution of isolated liquid phase region is searched out according to the boundary criterion, while and searching out each isolated
Distribution and circulation are re-started after the shrinkage cavity distribution of liquid phase region, until all isolated liquid phase regions disappear, to obtain final contracting
Pore size distribution realizes within the limited time, threedimensional model, corresponding material property parameter and the founder according to running gate system
Skill parameter relatively accurately simulates the position of shrinkage cavity, size and pattern under this casting technique, has to actual production good
Reference value.
As it will be easily appreciated by one skilled in the art that the foregoing is merely illustrative of the preferred embodiments of the present invention, not to
The limitation present invention, any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should all include
Within protection scope of the present invention.
Claims (6)
1. a kind of gravitational casting shrinkage cavity defect detection method based on dynamic pressure comprising following steps:
(1) threedimensional model for constructing running gate system initializes the running gate system in the solidification incipient stage, whole at this time
A molten metal region is that a father isolates liquid phase region；
(2) critical pressure needed for deriving the feeding resistance overcome between each isolated liquid phase region by the equation of motion of Darcy's law
Intensity values search out some time according to the boundary criterion using the critical pressure intensity values as the boundary criterion of isolated liquid phase area searching
The distribution for the isolated liquid phase region carved；If being carved with isolated liquid phase region at this time to exist, step 3 is turned to；Otherwise terminate；
(3) successively judge whether isolated liquid phase region divides and bury in oblivion, if division, turns to step 4, if isolated liquid phase region
It does not divide, then and then judges whether isolated liquid phase region buries in oblivion, if do not buried in oblivion, turn to step 4, otherwise turn to step 5；
(4) each isolated liquid phase region is marked, point of the shrinkage cavity based on boundary criterion search each isolated liquid phase region moment
After cloth, the contraction increment of each isolated liquid phase region is calculated, the smallest all grids of pressure in each isolated liquid phase region are simultaneously scanned for, with
The contraction increment of each isolated liquid phase region is divided equally and is added on all grids that search obtains；
(5) liquid fraction is calculated according to equilibrium equation " solid rate+liquid fraction+shrinkage cavity score=100% ", while updates all areas
Liquid fraction after, increase time step to subsequent time and go to step 2 and recycled, until all isolated liquid phase regions are equal
It disappears, to obtain final shrinkage cavity distribution.
2. the gravitational casting shrinkage cavity defect detection method based on dynamic pressure as described in claim 1, it is characterised in that: described
Rule of judgment whether critical pumping rate is isolated liquid phase region connection.
3. the gravitational casting shrinkage cavity defect detection method based on dynamic pressure as described in claim 1, it is characterised in that: derive
It will solidify what mushy zone was handled as porous media when the boundary criterion, wherein the feeding of the molten metal of solidification mushy zone
Speed is associated with the variation in temperature field；When searching for the distribution of isolated liquid phase region, it is assumed that be in each moment fluid quasi- quiet
State process, then fluid meets minimum potential energy principal in gravitational field.
4. the gravitational casting shrinkage cavity defect detection method based on dynamic pressure as described in claim 1, it is characterised in that: described
Critical pressure is calculated by following formula and is obtained:
Wherein, flFor liquid fraction, CTFor Models For Secondary Dendrite Arm spread ratio, ρsFor solid Density, ρlIt is viscosity, dx for density of liquid phase, μ
For space lattice step-length,It is temperature gradient for change of temperature field rate, G.
5. the gravitational casting shrinkage cavity defect detection method according to any one of claims 1-4 based on dynamic pressure, feature
Be: the distribution of shrinkage cavity is divided into three kinds of situations: if 1. isolating liquid phase region inner metal liquid and surrounding air, there is no contact surfaces, contract
Hole will be distributed over the isolated the smallest position of liquid phase region inner metal liquid pressure；2. such as isolated liquid phase region inner metal liquid and surrounding air
There are contact surfaces, and the minimum pressure in molten metal is greater than 0, then shrinkage cavity will be distributed over the isolated liquid phase region inner metal liquid and air
Contact surface on；3. as there are contact surfaces with surrounding air for isolated liquid phase region inner metal liquid, and minimum pressure is equal in molten metal
0, then shrinkage cavity will be distributed in the smallest position of contact surface and pressure of isolated the liquid phase region inner metal liquid and air simultaneously.
6. the gravitational casting shrinkage cavity defect detection method according to any one of claims 1-4 based on dynamic pressure, feature
Be: the contraction increment of isolated liquid phase region is calculated by following formula:
Wherein, Δ Ω is the volume of single grid, Δ VlFor the variable quantity of liquid volume in grid single in t to t+ Δ t, Δ fs
To solidify percentage, ρsFor solid Density, ρlFor density of liquid phase.
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| CN109655491B (en) * | 2019-01-15 | 2021-04-30 | 安徽奥特佳科技发展有限公司 | Method for detecting overall quality of defects of air holes and shrinkage cavities of aluminum alloy die castings |
| CN109871627B (en) * | 2019-02-26 | 2023-05-05 | 武汉晨曦芸峰科技有限公司 | Low-pressure casting hole loosening defect calculation method |
| CN110941916A (en) * | 2019-12-16 | 2020-03-31 | 重庆长安汽车股份有限公司 | Method for predicting microscopic shrinkage cavity of aluminum alloy casting based on casting simulation software |
| CN112517862B (en) * | 2020-11-20 | 2022-01-14 | 中国科学院金属研究所 | Secondary hole shrinkage control method for large-size high-temperature alloy master alloy cast ingot |
| CN115795741B (en) * | 2023-01-31 | 2023-04-14 | 北京适创科技有限公司 | Shrinkage cavity and shrinkage porosity prediction method and device, electronic equipment and storage medium |
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