CN105081288A - Experiment simulation device and method for studying solidification process of metal melt under temperature field and flow field coupled condition - Google Patents
Experiment simulation device and method for studying solidification process of metal melt under temperature field and flow field coupled condition Download PDFInfo
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Abstract
The invention discloses an experiment simulation device and method for studying the solidification process of a metal melt under a temperature field and flow field coupled condition. The device comprises a ceramic mold, wherein a temperature control assembly consisting of a plurality of temperature control units is mounted on the surface of the ceramic mold, the temperature control assembly is connected with a control computer, and heat insulating end plates are arranged at the two ends of the ceramic mold. The experiment simulation device further comprises a melt flow field driving device imbedded at the upper part of the ceramic mold. The temperature control assembly is connected with the control computer through a computer connecting port, and the computer connecting port is closely mounted with the temperature control assembly. The temperature control units comprise a cooling unit, a temperature measurement unit and a heating unit. The melt flow field driving device is an electromagnetic or mechanical pump.
Description
Technical field
The invention belongs to emtallurgy research equipment technical field, particularly a kind of experimental simulation device for studying metal bath process of setting under temperature field-flow field coupling condition and method.
Background technology
Along with the high speed development of national economy, metallurgy, the energy, traffic and the chemical field demand to heavy casting and forging grows with each passing day, and quality requirement also improves day by day, especially in fields such as the advanced energy, Aero-Space.At advanced energy field, although China has possessed design, manufactured the ability of conventional Supercritical unit, in the technology of preparing of heavy casting and forging, and still there is larger gap abroad.According to China's " heavy casting and forging industry 12 planning " report, China in 2007 needs the low pressure rotor demand of the steam turbine of more than 300MW unit, motor about about 201, and China only can provide less than 16, and all the other can only lean on import to solve.Planning is also pointed out simultaneously, and before the year two thousand twenty, China's water power and fired power generating unit heavy casting and forging demand estimate at about 2.7 ten thousand tons, will have huge breach between demand and market.At aviation and civil area, aviation high-strength/tenacity aluminum alloy as the melt casting process level of 7xxx system large gauge slab ingot (thickness is not less than 500mm) still lower, manufacturing capacity is still lower, if the overall localization rate of parts and components of typical high-performance aluminium alloy on the domestic airborne vehicles such as C919 and ARJ21 is also less than 30%.Because the general body of heavy castings is huge, service life is long, quality requirement is high, manufacture difficulty is large, add that production process consumes the energy and material etc. large, high in technological content, its manufacturing technology has become the major obstacle hindering the autonomous innovation of each field.Therefore, country the manufacture of heavy casting and forging has been classified as 12 plan give priority to object.The level of production wanting to improve the large foundry goods of China just must be studied the process of setting of large foundry goods, Solidification Characteristics.Because the large general material of foundry goods is special, size is large, casting technique is complicated, casting condition is harsh, the cost of once testing often arrives up to ten million left and right, so cannot conventionally by its casting technological parameter of large-scale experimental exploring millions of.Because the high temperature of heavy castings casting process, opaque feature, conventional direct observation, physical analogy cannot be carried out or method by inclining observing freezing interface, studying its process of setting by thermal analysis system.Meanwhile, because the metal freezing of a reality nonequilibrium process especially, so infer that the process of setting of metal also has certain deviation theoretically.
Chinese invention patent (CN104226952A) utilizes the solidification of metal melt process in the method simulation continuous casting steel billet casting process of directional solidification, the temperature field of its structure is comparatively simple, do not there is provided flow field simulation, be only applicable to temperature field comparatively simple, the casting process simulation that melt flows is inviolent.
Summary of the invention
The object of this invention is to provide a kind of experimental simulation device for studying metal bath process of setting under temperature field-flow field coupling condition and method, can accurate simulation heavy castings typical parts Solidification Characteristics, reproduce the metal solidification process in casting process, the solidified structure of prediction foundry goods.
The principle that realizes of the present invention is:
In casting solidification process, the growth of solidified structure crystal in other words is mainly subject to the impact in temperature field, flow field.And in heavy castings, the temperature field of privileged site and flow field are inconvenient to monitor.The reproduction that current casting simulation software can carry out to a certain degree by Finite Element Method to the temperature field of casting process and flow field has been proved in foundry practice for many years.If design a casting mould similar with the boundary condition of finite element modelling, by repeatedly numerical simulation and verification experimental verification, just can obtain the difference between simulated conditions and experiment condition, and then utilize experimental rig to simulate temperature field and the field of flow of heavy castings typical parts, just realize the simulation to heavy castings typical parts process of setting.
For this reason, the scheme that the present invention adopts as previously mentioned, crystal growing process in casting solidification process is mainly subject to the impact in temperature field and flow field, and this temperature field and flow field cannot be obtained by the method for physical observation or detection, and relatively reliable boundary condition can be provided for the simulation to foundry goods typical parts by finite element modelling, and obtain the experimental result consistent with actual curing condition.
Technical scheme of the present invention is, a kind of experimental simulation device for studying metal bath process of setting under temperature field-flow field coupling condition, this device comprises ceramic-mould, the temperature control assembly be made up of multiple temperature conditioning unit is installed on the surface of described ceramic-mould, this temperature control assembly controls computer be connected with one
At the two ends of described ceramic-mould, heat insulation end plate is housed,
Described experimental simulation device also comprises the melt flow field drive unit being placed into described ceramic-mould top.
Described temperature control assembly is connected with described control computer by a computer connectivity port, and installation is close to by this computer connectivity port and described temperature control assembly.
Described temperature conditioning unit comprises cooling unit, temperature measuring unit and heating unit.
Described melt flow field drive unit is electromagnetism or mechanical pump.
For studying an experimental simulation method for metal bath process of setting under temperature field-flow field coupling condition, it is characterized in that, comprise the following steps:
A1, the foundry goods object Geometric Modeling after utilizing finite element software to solidify metal bath casting, and carry out preliminary casting modeling and simulation of solidification, will occur in analog result that the typical component of defect carries out discretization, obtain the boundary condition of discrete locations;
A2, the three-dimensional dimension according to discrete locations builds casting mold, and casting mold adopts the ceramic-mould with higher heat resisting temperature;
A3, adopts the temperature control assembly be made up of multiple temperature conditioning unit, and the temperature of this temperature control assembly is carried out heating and cooling by a control computer to each temperature conditioning unit simultaneously controlled;
A4, is fixed on temperature control assembly on ceramic-mould wall, and the foundation in temperature field sets the temperature conditioning unit on ceramic-mould wall according to the boundary condition of finite element modelling by controlling computer machine;
A5, arranges a melt flow field drive unit at the upper opening place of ceramic-mould, the entry position of this melt flow field drive unit and exit position, Way in and Way out and power and all adjustable control of rotating speed;
A6, after finite element modelling result conditions setting and correlated variables condition, pours into casting mold by melt, carries out test simulation according to the finite element modelling feature of studied foundry goods and verifies.
Melt flow field drive unit described in steps A 5 is electromagnetism or mechanical pump, Way in, the Way out of pump set mechanically, flow velocity by changing the power of electromagnetic pump or mechanical pump, rotating speed controls, entry position and exit position drive mechanically, are moving apart from the metal bath surface programming degree of depth with the speed, the direction that control setting.
Also comprise steps A 7 further,
A7, adopts steps A 1 to A6, is optimized casting process, obtains the casting condition more optimized.
For studying an experimental simulation method for metal bath process of setting under temperature field-flow field coupling condition, it is characterized in that, comprise the following steps:
B1, carries out Geometric Modeling to studied heavy castings, and simulates with the casting process of setting of FEM model to heavy castings through the authenticated model validation of small-sized foundry goods;
B2, selects the typical parts easily occurring casting flaw, carries out 3D modeling to it, and according to 3D model preparation ceramic-mould;
B3, according to finite element modelling result, refines the temperature of built 3D model on heavy castings and Field Characteristics the boundary condition and the variable that become experimental simulation, the control computer of input experimental simulation device;
B4, installs the assembly of multiple temperature conditioning unit composition on ceramic-mould surface, and is connected with control computer;
B5, installs thermal insulation board additional at ceramic-mould two ends, and carries out preheating to it;
B6, is set to cast temperature by ceramic-mould temperature outside, and to casting metal melts in ceramic-mould;
B7, inserts on the upside of ceramic-mould by melt flow field drive unit, is entered, exports a little distance of below the melt liquid level that all submerges, and set entrance according to flow field direction;
B8, by the temperature conditioning unit outside ceramic-mould, arranges according to the thermo parameters method of finite element modelling result gained, and regulates each temperature conditioning unit temperature by change of temperature field situation;
B9, controls the entrance of melt flow field drive unit, and melt flow rate, inner for solidifying the molten bath part creation melt flows similar with the melt flow field in process of setting at ceramic-mould;
B10, under above-mentioned simulated conditions, melt cools and forms foundry goods in ceramic-mould, and this foundry goods is the solidified structure of heavy castings typical parts under institute's study condition.
A kind of experimental simulation method studied metal bath and solidify under temperature field-flow field coupling condition of the present invention, by adopting temperature control unit on a large scale, obtains the temperature field close with finite element modelling result outside ceramic-mould; By adding melt flow field drive unit at casting mold top, in ingot casting, obtain the temperature field (boundary condition that finite element modelling result use all pick up from large-sized casting ingot process of setting) close with finite element modelling result thus simulate temperature field in casting solidification process, flow field change completely, obtaining and solidified structure that actual casting solidification process is comparatively close.Utilize this method can will be easy in heavy castings occur that the process of setting of the typical parts of defect is by after the discrete separation of FInite Element, checking is obtained in small scale experiments, and without the need to carrying out casting process simulation to whole foundry goods and carrying out cutting analysis, which increase the casting research experiment feasibility of heavy castings.Utilize this method that the casting condition of experimental result to typical parts can be utilized to be optimized, backstepping goes out the optimization casting technique condition of heavy castings simultaneously, for heavy castings exploitation, manufacture reliable laboratory reference foundation is provided.
Accompanying drawing explanation
Fig. 1 is the experimental simulation method flow diagram under the heavy castings temperature field-flow field coupling in the embodiment of the present invention.
Fig. 2 is the experimental simulation device schematic diagram under the heavy castings temperature field-flow field coupling in the embodiment of the present invention.
Fig. 3 is the experimental simulation temperature control unit schematic diagram under the heavy castings temperature field-flow field coupling in the embodiment of the present invention.
Wherein, 1---ceramic-mould, 2---heat insulation end plate, 3---temperature conditioning unit, 4---melt flow field drive unit, 5---computer connectivity port, 6---control computer, 7---cooling unit, 8---temperature measuring unit, 9---heating unit.
Detailed description of the invention
Below in conjunction with example, the present invention is further illustrated as follows.As Fig. 1, and shown in composition graphs 2 and Fig. 3.
1). Geometric Modeling is carried out to studied heavy castings, and simulates with the casting process of setting of FEM model to heavy castings through the authenticated model validation of small-sized foundry goods;
2). select the typical parts easily occurring casting flaw, 3D modeling is carried out to it, and according to 3D model preparation ceramic-mould 1;
3). according to finite element modelling result, the temperature of built 3D model on heavy castings and Field Characteristics are refined the boundary condition and the variable that become experimental simulation, the control computer 6 of input experimental simulation device;
4). on ceramic-mould 1 surface, temperature control unit 3 be installed and be connected with control computer 6;
Install thermal insulation board 2 additional at ceramic-mould 1 two ends, and preheating is carried out to it;
6). ceramic-mould 1 temperature outside is set to cast temperature, and to casting metal melts in casting mold;
7). melt flow field drive unit 4 inserted on the upside of ceramic-mould, is entered, export below the melt liquid level that all submerges a little, and set entrance according to flow field direction;
8). by the temperature conditioning unit 3 outside ceramic-mould, arrange according to the thermo parameters method of finite element modelling result gained, and regulate each temperature conditioning unit temperature by change of temperature field situation;
9). control the entrance of melt flow field drive unit, and melt flow rate, inner for solidifying the molten bath part creation melt flows similar with the melt flow field in process of setting at ceramic-mould;
10). under above-mentioned simulated conditions, melt cools and forms foundry goods in ceramic-mould.This foundry goods is the solidified structure of heavy castings typical parts under institute's study condition.
The present invention is by utilizing temperature control unit on a large scale, the boundary temperature condition of simulation typical component in finite element process, and utilize flow field control unit, melt flow field in simulation typical component process of setting, realize the mode by realizing simulation heavy castings typical parts process of setting on a small scale, infer the coagulation defect occurrence law of whole heavy castings, and by parameter adjustment simulative optimization technique, the casting result after inspection process optimization.Because this analogy method has temperature field, the flow field simulation condition of general casting process, therefore this technology can extensively be generalized in the experimental simulation of other solidification of metal melt, casting field, for human and material resources, fund that the solidification simulation saving of casting field is a large amount of, and improve process exploitation efficiency.
Claims (8)
1. one kind for studying the experimental simulation device of metal bath process of setting under temperature field-flow field coupling condition, it is characterized in that, this device comprises ceramic-mould, the temperature control assembly be made up of multiple temperature conditioning unit is installed on the surface of described ceramic-mould, this temperature control assembly controls computer be connected with one
At the two ends of described ceramic-mould, heat insulation end plate is housed,
Described experimental simulation device also comprises the melt flow field drive unit being placed into described ceramic-mould top.
2. as claimed in claim 1 for studying the experimental simulation device of metal bath process of setting under temperature field-flow field coupling condition, it is characterized in that, described temperature control assembly is connected with described control computer by a computer connectivity port, and installation is close to by this computer connectivity port and described temperature control assembly.
3. as claimed in claim 1 for studying the experimental simulation device of metal bath process of setting under temperature field-flow field coupling condition, it is characterized in that, described temperature conditioning unit comprises cooling unit, temperature measuring unit and heating unit.
4. as claimed in claim 1 for studying the experimental simulation device of metal bath process of setting under temperature field-flow field coupling condition, it is characterized in that, described melt flow field drive unit is electromagnetism or mechanical pump.
5., for studying an experimental simulation method for metal bath process of setting under temperature field-flow field coupling condition, it is characterized in that, comprise the following steps:
A1, the foundry goods object Geometric Modeling after utilizing finite element software to solidify metal bath casting, and carry out preliminary casting modeling and simulation of solidification, will occur in analog result that the typical component of defect carries out discretization, obtain the boundary condition of discrete locations;
A2, the three-dimensional dimension according to discrete locations builds casting mold, and casting mold adopts the ceramic-mould with higher heat resisting temperature;
A3, adopts the temperature control assembly be made up of multiple temperature conditioning unit, and the temperature of this temperature control assembly is carried out heating and cooling by a control computer to each temperature conditioning unit simultaneously controlled;
A4, is fixed on temperature control assembly on ceramic-mould wall, and the foundation in temperature field sets the temperature conditioning unit on ceramic-mould wall according to the boundary condition of finite element modelling by controlling computer machine;
A5, arranges a melt flow field drive unit at the upper opening place of ceramic-mould, the entry position of this melt flow field drive unit and exit position, Way in and Way out and power and all adjustable control of rotating speed;
A6, after finite element modelling result conditions setting and correlated variables condition, pours into casting mold by melt, carries out test simulation according to the finite element modelling feature of studied foundry goods and verifies.
6. as claimed in claim 5 for studying the experimental simulation method of metal bath process of setting under temperature field-flow field coupling condition, it is characterized in that, melt flow field drive unit described in steps A 5 is electromagnetism or mechanical pump, Way in, the Way out of pump set mechanically, flow velocity by changing the power of electromagnetic pump or mechanical pump, rotating speed controls, entry position and exit position drive mechanically, are moving apart from the metal bath surface programming degree of depth with the speed, the direction that control setting.
7., as claimed in claim 5 for studying the experimental simulation method of metal bath process of setting under temperature field-flow field coupling condition, it is characterized in that, also comprise steps A 7 further,
A7, adopts steps A 1 to A6, is optimized casting process, obtains the casting condition more optimized.
8., for studying an experimental simulation method for metal bath process of setting under temperature field-flow field coupling condition, it is characterized in that, comprise the following steps:
B1, carries out Geometric Modeling to studied heavy castings, and simulates with the casting process of setting of FEM model to heavy castings through the authenticated model validation of small-sized foundry goods;
B2, selects the typical parts easily occurring casting flaw, carries out 3D modeling to it, and according to 3D model preparation ceramic-mould;
B3, according to finite element modelling result, refines the temperature of built 3D model on heavy castings and Field Characteristics the boundary condition and the variable that become experimental simulation, the control computer of input experimental simulation device;
B4, installs the assembly of multiple temperature conditioning unit composition on ceramic-mould surface, and is connected with control computer;
B5, installs thermal insulation board additional at ceramic-mould two ends, and carries out preheating to it;
B6, is set to cast temperature by ceramic-mould temperature outside, and to casting metal melts in ceramic-mould;
B7, inserts on the upside of ceramic-mould by melt flow field drive unit, is entered, exports a little distance of below the melt liquid level that all submerges, and set entrance according to flow field direction;
B8, by the temperature conditioning unit outside ceramic-mould, arranges according to the thermo parameters method of finite element modelling result gained, and regulates each temperature conditioning unit temperature by change of temperature field situation;
B9, controls the entrance of melt flow field drive unit, and melt flow rate, inner for solidifying the molten bath part creation melt flows similar with the melt flow field in process of setting at ceramic-mould;
B10, under above-mentioned simulated conditions, melt cools and forms foundry goods in ceramic-mould, and this foundry goods is the solidified structure of heavy castings typical parts under institute's study condition.
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| CN111208016A (en) * | 2020-02-12 | 2020-05-29 | 东北大学 | Continuous casting billet surface crack propagation critical strain measurement and crack propagation prediction method |
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