CN110961617B - Aluminum liquid pouring simulation method - Google Patents
Aluminum liquid pouring simulation method Download PDFInfo
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- CN110961617B CN110961617B CN201911082547.XA CN201911082547A CN110961617B CN 110961617 B CN110961617 B CN 110961617B CN 201911082547 A CN201911082547 A CN 201911082547A CN 110961617 B CN110961617 B CN 110961617B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D45/00—Equipment for casting, not otherwise provided for
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- G09B25/00—Models for purposes not provided for in G09B23/00, e.g. full-sized devices for demonstration purposes
- G09B25/02—Models for purposes not provided for in G09B23/00, e.g. full-sized devices for demonstration purposes of industrial processes; of machinery
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Abstract
The invention provides a liquid aluminum pouring simulation method, which belongs to the technical field of alloy forming and comprises the following steps: selecting a transparent hard material, reducing the size according to a preset proportion, and manufacturing a rotary ladle model, a stirrer model, a heat preservation furnace model and a mould model; introducing simulation liquid into the ladle model, and stirring the simulation liquid in the ladle model by using the stirrer model; and pouring the stirred simulation liquid into a heat preservation furnace model, pressurizing the simulation liquid in the heat preservation furnace model, and allowing the simulation liquid to enter the mold model from the heat preservation furnace model. According to the aluminum liquid pouring simulation method provided by the invention, the model is reduced and manufactured according to the preset proportion, and the simulation forming is completed. The simulation liquid is visually observed through the model made of the transparent material, and the flowing condition of the simulation liquid in each model is known, so that the corresponding improvement of process design and process control of related personnel can be facilitated.
Description
Technical Field
The invention belongs to the technical field of alloy forming, and particularly relates to a method for simulating molten aluminum pouring.
Background
Aluminum alloy wheel hub is in process of production, smelt aluminium ingot and functional metal into aluminium liquid in smelting the big stove earlier, get into the turn-packet through the chute again, carry out rotor degassing refining back to aluminium liquid in the turn-packet, pass on to the holding furnace in die casting machine lower part through the turn-packet, aluminium liquid flow condition changes always at this in-process, the change of aluminium liquid flow in-process can influence the internal structure form of product, influence its mechanical properties, violent change when aluminium liquid flows, if disturbance, strike the phenomenon of seething even, can influence the final quality of product, cause the product to scrap when serious.
However, in actual production, the whole flowing process of the aluminum liquid is difficult to observe, and the mold can be designed and the casting process can be controlled only by experience and imagination, so that deviation occurs in process design and process control, and the product quality is influenced; at present, the flowing and filling of the aluminum liquid can be simulated by using a digital simulation method, but the price of software is higher, and the software can be simulated by using the software with higher skills.
Disclosure of Invention
The invention aims to provide a method for simulating molten aluminum pouring, aiming at solving the problems that in the actual production, the whole flowing process of molten aluminum is difficult to observe, and the process design and the process control are deviated due to the fact that a mould is designed and the casting process is controlled only by experience and imagination, so that the product quality is influenced; the digital analog simulation software is used, the price is high, and the software can be used for simulation only by high skill.
In order to achieve the purpose, the invention adopts the technical scheme that: the method for simulating molten aluminum pouring comprises the following steps:
selecting a transparent hard material, reducing the size according to a preset proportion, and manufacturing a rotary ladle model, a stirrer model, a heat preservation furnace model and a mould model;
introducing simulation liquid into the ladle model, and stirring the simulation liquid in the ladle model by using the stirrer model;
and pouring the stirred simulation liquid into the heat preservation furnace model, pressurizing the simulation liquid in the heat preservation furnace model, and enabling the simulation liquid to enter the mold model from the heat preservation furnace model.
As another embodiment of the present application, a launder model is reduced and manufactured in the predetermined proportion, and the simulation liquid is introduced into the ladle model through the launder model.
As another embodiment of the present application, the predetermined ratio is 10: 1.
as another embodiment of the present application, the transparent hard material is a transparent acrylic material.
As another example of the present application, the simulant is dyed water.
As another embodiment of the present application, the simulation liquid and the aluminum liquid need to satisfy the condition that Froude number and Reynolds number are equal under the condition of geometric similarity.
As another embodiment of the present application, graduation marks are marked on the subcontracting model at intervals of 10 mm.
As another embodiment of the present application, the simulation liquid in the holding furnace model is pressurized by introducing high-pressure gas into the holding furnace model, and the mold cavity of the mold model is evacuated.
The aluminum liquid pouring simulation method provided by the invention has the beneficial effects that: compared with the prior art, the molten aluminum pouring simulation method is characterized in that a ladle model, a stirrer model, a holding furnace model and a mold model are reduced and manufactured according to a preset proportion, a plurality of models are connected according to an actual production process flow sequence, and simulation liquid passes through the models in sequence and finally enters the mold model to complete simulation forming. The simulation liquid is visually observed through the model made of the transparent material, and the flowing condition of the simulation liquid in each model is known, so that the corresponding improvement of process design and process control of related personnel can be facilitated.
Detailed Description
In order to make the technical problems, technical solutions and advantageous effects to be solved by the present invention more apparent, the present invention is further described in detail below with reference to the following embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
Now, the method for simulating molten aluminum pouring provided by the invention will be explained. A molten aluminum pouring simulation method comprises the following steps:
selecting a transparent hard material, reducing the size according to a preset proportion, and manufacturing a rotary ladle model, a stirrer model, a heat preservation furnace model and a mould model;
introducing simulation liquid into the ladle model, and stirring the simulation liquid in the ladle model by using the stirrer model;
and pouring the stirred simulation liquid into a heat preservation furnace model, pressurizing the simulation liquid in the heat preservation furnace model, and allowing the simulation liquid to enter the mold model from the heat preservation furnace model.
Compared with the prior art, the ladle model, the stirrer model, the holding furnace model and the mold model are reduced and manufactured according to the preset proportion, and compared with the method that a plurality of models are connected according to the actual production process flow sequence, the simulation liquid passes through the models in sequence and finally enters the mold model to complete the simulation forming, the simulation method is simple in supported device, simple and convenient to operate and low in cost. The simulation liquid is visually observed through the model made of the transparent material, and the flowing condition of the simulation liquid in each model is known, so that the corresponding improvement of process design and process control of related personnel can be facilitated.
The production mode of casting the hubs is mainly low-pressure casting, and molten aluminum used for casting is poured into a heat preservation furnace through a ladle so as to be cast. However, before this, the aluminum liquid in the ladle needs to be stirred by a stirrer to achieve the purpose of removing impurities in the aluminum liquid, and the stirrer has the function of purifying the quality of the aluminum liquid.
At present, a stirrer is a motor-driven shaft type physical stirrer, a stirrer model is manufactured by referring to the stirrer in actual production, and the stirrer model is divided into a mechanical stirring part and an electrical control part. The electric control part is mainly a control circuit for controlling the rotation of the motor, the control circuit consists of a direct current motor and a 24V direct current power supply, and the rotation of the direct current motor is controlled by a control circuit contactor, so that the effect of stirring the simulation liquid in the rotary ladle model can be achieved. The mechanical stirring part is driven to rotate by controlling a motor, so that the simulation liquid in the rotary ladle mold is stirred, and the stirring condition of the aluminum liquid in the rotary ladle rotating along with the rotating shaft is simulated. The direct current motor is provided with a speed regulation control circuit, the speed regulation and control of the direct current motor can be realized through the speed regulation control circuit, alternating current voltage can be converted into direct current voltage, and the speed regulation and control of the direct current motor can be realized through the voltage conversion and the control of a given voltage circuit. The speed regulating range of the direct current motor is controlled to be 0-500 rpm, the rotating speed of the actual stirrer model rotor is 420-245 rpm, speed switching and test development can be better achieved, and a speed regulating button can be added to the control circuit, so that speed regulation is facilitated.
The mechanical stirring part and the electrical control part of the stirrer model are connected through a support frame, the motor is fixed on a bottom plate of the support frame after the two parts are manufactured, and a rotating shaft, a rotating rotor and a motor control box are assembled to form the integral stirrer model.
As a specific implementation mode of the aluminum liquid pouring simulation method provided by the invention, the launder model is reduced and manufactured according to a preset proportion, and simulation liquid is introduced into the ladle model through the launder model. In this embodiment, the proportion of the launder model is made according to a predetermined proportion, the launder model is placed above the ladle model, the outlet end of the launder model is positioned right above the ladle, the simulation liquid falls into the ladle model from the outlet end of the launder model, and the stirring, impact or tumbling condition of the aluminum liquid when the aluminum liquid falls into the ladle from the large smelting furnace is simulated by using the height difference between the simulation liquid and the ladle model in actual production.
As a specific implementation mode of the molten aluminum pouring simulation method provided by the invention, the preset proportion is 10: 1. in the embodiment, the actual size of the 1.5T ladle is reduced to 1/10, and the aluminum liquid pouring simulation physical model is established on the basis of the 1.5T ladle. The size of the inner cavity of the 1.5T molten aluminum ladle is phi 868mm in inner diameter and 1100mm in height, the inner diameter and phi 86.8mm in height of the manufactured ladle model are phi 110mm, and a stirrer model, a heat preservation furnace model and a mold model are manufactured for the size based on the ladle model.
As a specific implementation mode of the aluminum liquid pouring simulation method provided by the invention, the transparent hard material is a transparent acrylic material. In this example, acryl, also known as PMMA or plexiglass, is available from acrylic, which is also known by the chemical name polymethylmethacrylate. Ya li ke is an important plastic high polymer material which is developed earlier, has better transparency, chemical stability and weather resistance, is easy to dye, process and beautiful in appearance, and is widely applied to the building industry. And transparent acrylic materials are adopted, so that the flowing condition of the simulation liquid in each model can be conveniently observed.
As a specific implementation mode of the aluminum liquid pouring simulation method provided by the invention, the simulation liquid is dyeing water. In the embodiment, the self color of the dyeing water is utilized, so that the observation is convenient. The dyeing water can be purified water or distilled water as a solution, a small amount of starch is added into the solution, and the purified water or distilled water is subjected to heating treatment at the same time, so that the temperature of the solution is ensured to be 40-60 ℃, the starch can be ensured to be fully dissolved in the purified water or distilled water, the solution has certain viscosity, and the flowing condition of aluminum liquid can be simulated more truly. In addition, a small amount of iodine solution is added into the purified water or the distilled water, the ratio of the iodine solution to the solution is 1/100, and after the iodine solution meets the starch, the simulation solution is blue, so that the dyeing water convenient to observe is formed.
As a specific implementation mode of the aluminum liquid pouring simulation method provided by the invention, under the condition that the simulation liquid and the aluminum liquid are geometrically similar, the Froude number and the Reynolds number need to be equal. In this embodiment, the geometric similarity between the simulation liquid and the molten aluminum means that the simulation liquid and the molten aluminum reflect the relative relationship between the pressure drop of the flow field and the dynamic pressure head thereof, and the relative magnitude of the momentum loss rate in the flow process is reflected. The Froude number is also called Froude (Froude ) number, and the mechanical significance of the Froude number is the comparison relationship between the inertia force and the gravity of water flow: fr>1, the inertia force plays a leading role in water flow, and the water flow is rapid; when Fr is less than 1, gravity plays a leading role, and water flow is slow flow; when Fr is equal to 1, the gravity and the inertia force are equal, the water flow is critical flow,
froude number, also known as reynolds number, is a dimensionless number in fluid mechanics where reynolds number is a measure of the ratio of the inertial force to viscous force of a fluid. When the Reynolds number is smaller, the influence of the viscous force on the flow field is larger than the inertia force, the disturbance of the flow velocity in the flow field is attenuated due to the viscous force, the fluid flows stably and is laminar flow; on the contrary, if the reynolds number is larger, the influence of the inertia force on the flow field is larger than the viscous force, the fluid flow is unstable, the small change of the flow velocity is easy to develop and strengthen, and disorder and no flow occursThe regular turbulent flow field is formed by the flow field,
rho in the above relation is simulated water density, ν is simulated water filling speed, l is simulated water flowing distance, mu is liquid viscosity, and g is gravity acceleration; rho ' is the simulated water density, ν ' is the simulated water filling speed, l ' is the simulated water flowing distance, mu ' is the liquid viscosity, and g ' is the gravity acceleration.
The Froude number and the Reynolds number of the simulated water should be the same as the relevant numerical values of the actual aluminum liquid, so that the optimal simulation effect can be achieved, and the flowing condition of the actually produced aluminum liquid can be reproduced through the simulated water.
As a specific implementation mode of the aluminum liquid pouring simulation method provided by the invention, scale marks are marked on the ladle model at intervals of 10 mm. In the embodiment, the scale marks are marked on the side wall of the ladle model, and the liquid level height of the simulation liquid in the ladle model is marked from top to bottom, so that the liquid level height of the simulation liquid can be conveniently observed, and the liquid level height of the aluminum liquid in actual production can be conveniently simulated.
As a specific implementation mode of the aluminum liquid pouring simulation method provided by the invention, the simulation liquid in the heat preservation furnace model is pressurized in a mode of introducing high-pressure gas into the heat preservation furnace model, and the mold cavity of the mold model is vacuumized. In the embodiment, the upper part of the side wall of the heat preservation furnace model is provided with an air inlet, and high-pressure air is introduced into the heat preservation furnace model through the air inlet; and an air exhaust hole is formed in the upper part of the mold model, and the inner cavity of the mold model is vacuumized by utilizing the air exhaust hole. And the simulated water in the heat preservation furnace model enters the inner cavity of the mold model through the lift pipe under the action of the pressure difference between the heat preservation furnace model and the mold model, so that the simulated water is used for simulating the aluminum liquid filling. The air pressure of the high-pressure gas introduced into the heat preservation furnace model is 15-20 kpa, the air pressure value is selected according to the size of the corresponding heat preservation furnace model calculated by a 1.5T subcontracting model core, when the size of the heat preservation furnace model is increased, the air pressure of the high-pressure gas is increased along with the increase of the air pressure value, and the increased value is increased in direct proportion to the volume of the heat preservation furnace model.
As a specific implementation mode of the molten aluminum pouring simulation method provided by the invention, the simulation liquid is introduced into the ladle model, and simultaneously, the particulate matters are added into the ladle model. In this embodiment, the smelting of aluminium liquid is gone on in smelting the big stove, need take off the sediment and handle, get rid of the impurity on aluminium liquid surface, guarantee the purity of aluminium liquid as far as possible, but aluminium liquid gets into the subcontracting back from smelting the big stove, the surface of aluminium liquid still can form one deck oxide film, the subcontracting is constantly poured into along with aluminium liquid, or when supplementeing aluminium liquid in the subcontracting, the oxide film in the subcontracting can be stirred into aluminium liquid, form bulk or flocculent inclusion, during the casting, these inclusions pass through stalk entering mould die cavity, cause product surface slag point or inside defect of mingling, influence the quality of product. The molten aluminum in the rotary ladle is stirred, so that impurities float on the upper surface of the molten aluminum, and the impurities in the molten aluminum are reduced to enter the heat preservation furnace from the rotary ladle, thereby ensuring the internal quality of a molded product.
The particles are selected to be different in density and shape, the density of one particle is slightly smaller than that of the simulation liquid, the density of the other particle is the same as that of the simulation liquid, and the particles can adopt a flocculent or agglomerate structure and are used for simulating inclusions in the molten aluminum. The simulation liquid is introduced into the rotary ladle model and simultaneously particles are continuously added, the simulation liquid simulates the aluminum liquid, the simulation liquid has certain viscosity, after the particles with different densities and different shapes enter the simulation liquid, part of the particles can be suspended in the simulation liquid under the impact action when the simulation liquid enters the rotary ladle model, part of the particles can float on the surface of the simulation liquid, and the particles distributed at different positions in the simulation liquid are used for simulating inclusions in the aluminum liquid or inclusions floating on the surface of the aluminum liquid in the actual production.
In order to conveniently record the flowing condition of the simulation liquid, cameras are arranged on each model and the side of the flowing channel, the flowing process of the simulation liquid can be observed and recorded at any time, the cameras collect images or photos, transmit the images or the photos to a PC end in a centralized mode, analyze and compare the images or the photos, observe and compare the images or the photos to obtain the most intense flowing area of the simulation liquid, and the models in the area are improved to include the shape, the volume or the positions of an inlet and an outlet of a model inner cavity, so that the optimal model configuration is obtained through adjustment, actual production equipment is further improved, the flowing of the aluminum liquid in the actual production equipment is smoother, the phenomena of disturbance, impact and even churning of the flowing process of the aluminum liquid are reduced, and the quality of a formed product is improved.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, as any variations, equivalents, or improvements made within the spirit and principles of the present invention are intended to be included therein.
Claims (6)
1. A molten aluminum pouring simulation method is characterized by comprising the following steps:
selecting a transparent hard material, reducing the size according to a preset proportion, and manufacturing a rotary ladle model, a stirrer model, a heat preservation furnace model and a mould model;
introducing simulation liquid into the ladle model, and stirring the simulation liquid in the ladle model by using the stirrer model;
pouring the stirred simulation liquid into the heat preservation furnace model, pressurizing the simulation liquid in the heat preservation furnace model, and enabling the simulation liquid to enter the mold model from the heat preservation furnace model;
reducing and manufacturing a launder model according to the preset proportion, introducing the simulation liquid into the rotary ladle model through the launder model, adding particles into the rotary ladle model while introducing the simulation liquid into the rotary ladle model, wherein the particles are selected from different densities and different shapes, the density of one particle is slightly smaller than that of the simulation liquid, the density of the other particle is the same as that of the simulation liquid, the particles can adopt a flocculent or agglomerate structure, and after the particles with different densities and different shapes enter the simulation liquid, part of the particles can be suspended in the simulation liquid and part of the particles can float on the surface of the simulation liquid under the impact action when the simulation liquid enters the rotary ladle model;
the simulation liquid is dyeing water; the dyeing water adopts purified water or distilled water as a solution, a small amount of starch is added into the solution, and the purified water or distilled water is subjected to heating treatment at the same time to ensure that the temperature is between 40 and 60 ℃ so that the solution has certain viscosity; a small amount of iodine solution is added into purified water or distilled water, the ratio of the iodine solution to the solution is 1/100, and the iodine solution can make the simulated solution become blue after meeting starch.
2. The molten aluminum pouring simulation method of claim 1, wherein the predetermined ratio is 10: 1.
3. the aluminum liquid pouring simulation method as claimed in claim 1, wherein the transparent hard material is a transparent acrylic material.
4. The aluminum liquid pouring simulation method as claimed in claim 1, wherein the simulation liquid and the aluminum liquid need to satisfy the condition of Froude number and Reynolds number being equal under the condition of geometric similarity.
5. The molten aluminum pouring simulation method of claim 1, wherein scale marks are marked on the ladle model at intervals of 10 mm.
6. The molten aluminum pouring simulation method of claim 1, wherein the simulation liquid in the holding furnace model is pressurized by introducing high-pressure gas into the holding furnace model, and the mold cavity of the mold model is evacuated.
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Application publication date: 20200407 Assignee: BAODING LIZHONG DONG'AN LIGHT ALLOY PARTS CO.,LTD. Assignor: BAODING LIZHONG WHEEL MANUFACTURING Co.,Ltd. Contract record no.: X2023990000004 Denomination of invention: A simulation method of molten aluminum pouring Granted publication date: 20211207 License type: Common License Record date: 20230112 |