CN106709180A - Numerical simulation method for superfine cemented carbide step round bar PIM (Powder Injection Molding) mold filling process - Google Patents

Numerical simulation method for superfine cemented carbide step round bar PIM (Powder Injection Molding) mold filling process Download PDF

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CN106709180A
CN106709180A CN201611196887.1A CN201611196887A CN106709180A CN 106709180 A CN106709180 A CN 106709180A CN 201611196887 A CN201611196887 A CN 201611196887A CN 106709180 A CN106709180 A CN 106709180A
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powder
mold filling
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binder
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谢兴铖
曹瑞军
林中坤
林晨光
李忠武
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GRIMN Engineering Technology Research Institute Co Ltd
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Beijing General Research Institute for Non Ferrous Metals
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Abstract

The invention relates to a numerical simulation method for a superfine cemented carbide step round bar PIM (Powder Injection Molding) mold filling process. Through equivalent powder, a multi-fluid model, the optimization of fluid inlets and outlets, the refining of a mesh model and the reasonable setting of the mutual function of a fluid pair, the astringency of a simulation process is effectively improved, the problem that calculation is likely to be divergent due to the big density difference, the big viscosity difference, small interface interaction depth and the like of binder and powder can be overcome, the visualization of a feeding melt mold filling flowing process is realized, mold filling characteristics, including respective speed, temperature and viscosity physical field distribution, of the powder and the binder can be effectively mastered, a binder formula is optimized, and a critical powder loading amount is determined so as to improve the PIM technology of the superfine cemented carbide. The method can be used for investigating defects including bubbles, defects and the like in a mold filling process, a root for generating segregation and the influence factor of the root are analyzed, defect generation information, including cracks, air holes, weld bonds and the like, can be predicted, and useful information is provided for analyzing superfine cemented carbide PIM technological conditions and feeding properties, guiding technological parameters and mold design.

Description

A kind of method for numerical simulation of ultra-fine cemented carbide step pole PIM mold filling processes
Technical field
The invention belongs to powder metallurgy near-net-shape technical field, more particularly to a kind of ultra-fine cemented carbide step pole The method for numerical simulation of PIM mold filling processes.
Background technology
Superfine WC-Co cemented carbide, due to its high intensity, high rigidity and high-wearing feature, is widely used in instrument, mould And wear part, many fields such as including metal cutting tool, wire drawing and press forming die, sealing ring, nozzle.
Ultra-fine cemented carbide powder injection moulding (PIM), can not only obtain the alloy of high intensity, high rigidity and high abrasion, And can prepare the near-net-shape product of complicated shape, with incomparable excellent of conventional powder metallurgical and machine-tooled method Gesture.
The mold filling process of powder injection forming is a non-isothermal for non-newtonian fluid, unsteady Complex Flows, is one The individual powder particle including solid phase, the binding agent of liquid phase and in die cavity gas Multiphase Flow process.Due to ultrafine WC/Co mixing There is particle agglomeration in material, tap density is only the 25~40% of solid density;Powder reunion is still suffered from ultrafine WC/Co feedings Grain, binding agent parcel WC/Co particles are insufficient, and feeding heat endurance is low, and powder is reunited and causes ultra-fine feeding mobility reduction width Degree up to 60%, production process is difficult to efficiently control, experimental study high cost.It is right with the development of computer technology Debugging repeatedly and makeover process in traditional mould production, numerical simulation can effectively Optimizing Process Parameters, raising mould Quality, reduces production cost.And it is current, have no the relevant report of ultra-fine cemented carbide injection moulding mold filling process numerical simulation.
The content of the invention
In view of the shortcomings of the prior art, the invention provides a kind of number of ultra-fine cemented carbide step pole PIM mold filling processes Value analogy method.
The technical solution adopted by the present invention is as follows:
A kind of method for numerical simulation of ultra-fine cemented carbide step pole PIM mold filling processes, comprises the following steps:
1) model simplification is carried out to step pole, setting mold filling entrance is exported with mold filling, sets up step pole three-dimensional geometry Model;
2) to step 1) the step pole 3-D geometric model carries out mesh generation, sets up FEM model;
3) to step 2) FEM model carries out physical definition, according to the behaviour of live ultra-fine cemented carbide injection moulding Make environment and in the case where not influenceing to calculate accuracy, gas-liquid-solid multiphase flow filling flow process in die cavity is assumed And simplification, it is specific to set as follows:
A () defines multithread phase material:Respectively name WC/Co compounds, binder mixtures and air be powder, Binder and air, defines the respective parameter of powder, binder and air, including thermodynamic state, molal weight, theory respectively Density, specific heat, viscosity, the coefficient of heat conduction;
B () defines analog type:Selection Unsteady State Simulation, setting time parameter;
C () defines heterogeneous fluid domain:For step pole creates domain, fluid model and fluid details are defined;
D () defines boundary condition:Side including mold filling entrance (inlet), mold filling outlet (outlet) and die wall (wall) Boundary's condition, provides specific boundary condition respectively;Temperature, pressure in setting initial value, including die cavity, powder in die cavity, The respective speed of binder and air and volume fraction;
E () setting solves control:Selecting divalence Euler's formula solving precision backward, physical descriptor includes viscosity, pressure, speed Degree, temperature, density, hot-fluid, volume fraction;
4) numerical simulation calculation:Solved using finite volume method, and information is solved by residual sum and checked meter in time Problem present in calculation and/or check the order of accuarcy of solution;
5) visual analyzing is carried out to convergent simulation result of calculation, obtain powder in mold filling process,
The respective VELOCITY DISTRIBUTIONs of binder and air, Temperature Distribution, pressure distribution, volume fraction distribution, viscosity profile, point Influence of the analysis technological parameter to mold filling process, optimize binder formula, determine that the critical powder of feeding of WC/Co compounds is loaded Amount.
Step 1) in, it is mold filling entrance with the actual cast gate of die cavity, exported by mold filling of cast gate distal end.
Step 2) the middle tetrahedral grid division using non-structural, global grid size is 0.2mm, wherein, mould intracavity wall, Mold filling entrance inwall and mold filling outlet inside wall are in arc-shaped, after tetrahedral grid is generated, reuse triangular prism mesh refinement circle Arc edge, through checking mesh quality to reach 0.4, meets and calculates requirement.
Step 3) in (a), the WC powder granularity of WC/Co compounds is 0.2 μm~0.6 μm, and the weight/mass percentage composition of Co is 6%~15%;The material parameters of binding agent are theoretical calculation, bibliography or actual measurement gained.
Step 3) in (b), total duration is set as 0.05s, time step are 5 × 10-5S, initial time are 0s.
Step 3) it is that step pole creates domain in (c), it is named as STEP BAR;Open buoyancy model, buoyancy reference density It is 1.185gcm-3;The reference pressure of domain model is 1atm;Buoyancy model be Buoyant, Y-direction acceleration of gravity be-g, X, Z-direction acceleration of gravity is 0ms-2, buoyancy reference density is set as three density of the smaller phase of phase Midst density, i.e. air is close Degree;Domain is set as static;Mesh free deforms.
Step 3) in (c), multiphase option is set to heterogeneous in fluid simulation, and heat transmission model is set to heat content energy, Turbulence model is set to laminar model.
Step 3) in (c), in fluid simulation fluid (air | binder) and (air | powder) alternate transmission is from By surface model, surface tension coefficient is set to 0.072Nm-1, dragging force coefficient is 0.44Pa-1·s-1, without mass transfer; Fluid is mixed model to (binder | powder) alternate transmission, interface alternation depth be set to 0.2 μm~0.6 μm, drag force Coefficient is 0.44Pa-1·s-1~14.4Pa-1·s-1
Step 3) in (d), the boundary condition of mold filling entrance (inlet) is to set fluid as subsonic speed, and quality and momentum set It is set to 0~20ms of standard speed-1, heat transmission is set as static temperature 423K, powder, binder and air in fluid value Volume fraction be respectively Wherein,Mold filling is exported (outlet) boundary condition is to set fluid as subsonic speed, and quality and momentum are set as averaged static pressure, and relative pressure is 0Pa, hybrid cytokine is 0.05;Die wall (Wall) boundary condition is set as that, without sliding, heat transmission temperature is 298K.
Step 3) in (d), initial value setting:Temperature T=298K, pressure P=1atm in given t=0 moment die cavitys, The speed of powder, binder and air is vp=vb=vaThe volume fraction of=0.0001m/s, airPowder and The volume fraction of binder is
Step 3) in (e), convergence calculates minimum step number in control be that 1 step, maximum step number are 100 steps, and convergence scheme is equal Square residuals value RMS=1 × 10-4, transient time step is 10 steps.
Step 4) in, numerical simulation is using the powder-binding agent multi-phase model based on finite volume method, it is assumed that powder Grain is the continuous media that exist jointly and can interpenetrate in space optional position with binding agent, and powder belongs to that with binding agent This two kinds of fluid that are independent and interacting.
Further, in the multi-phase model, do not undergone phase transition at boundary, two alternate massless are exchanged, and are neglected Slightly pulse item, meet two-phase current mass, momentum and the energy conservation equation obtained with averaging method, PIM filling flow processes Reynolds number it is smaller, can use Nu ≈ 2, its drag force uses mixed model.
Beneficial effects of the present invention are:
The present invention is by equivalent powder, multi-phase model, optimization stream socket, tessellated mesh model, reasonable set stream Body Thermodynamic parameters, can effectively improve the convergence of simulation process, and the density contrast for overcoming binding agent and powder is big, differences in viscosity Greatly, the problem of the interface alternation depth calculating for causing such as small easily diverging, realizes the visualization of feeding melt intercalation process, The mold filling characteristic such as powder and the respective speed of binding agent, temperature and viscosity physics field distribution can be effectively grasped, optimizes binding agent Formula, determines critical powder loading, so as to improve its PIM technique.The present invention can be used to investigate ultra-fine cemented carbide feeding Bubble in mold filling process, the defect such as collapse, the segregation for analyzing mold filling process produces root and its influence factor, and predictive PI M fills The defect such as crackle, stomata, weld bond produces information in mold process, is analysis ultra-fine cemented carbide PIM process conditions and feeding Matter, instruct technological parameter and mold design offer useful information.
Simulation process of the invention is easily compared with result with experimental result, and model amount of calculation is small, and primary condition is easy It is easy to application in result that is given and trying to achieve.
Brief description of the drawings
Fig. 1 is (a) UG models and (b) FEM model of ultrafine WC/10Co hard alloy PIM mold filling die cavitys in embodiment Schematic diagram.
Fig. 2 is the feeding melt volume point in ultrafine WC/10Co feeding mold filling processes on the central plane of cast gate Number distribution and powder temperature changes in distribution figure.
Fig. 3 be embodiment in ultrafine WC/10Co hard alloy PIM mold filling 0.03s when longitudinal centre line on binding agent and powder End speed difference distribution map, wherein, powder loading is 49%, cast gate for Z=31mm at.
Fig. 4 be embodiment in powder loading to (a) binding agent in ultrafine WC/10Co hard alloy PIM mold filling processes with (b) powder along cast gate direction volume fraction distribution influence figure, wherein, X=2.8mm be cast gate at.
Fig. 5 is influence (cast gate at level of the powder loading to the distribution of the volume fraction of powder and binding agent in embodiment Section).
Fig. 6 is influence of the different powder loadings to WC-10Co alloy properties:(a) hardness and bending strength;(b) density; C () is with respect to magnetic saturation.
Specific embodiment
The present invention will be further described with reference to the accompanying drawings and detailed description.It is emphasized that the description below It is merely exemplary, rather than in order to limit the scope of the present invention and its application.
So that ultrafine WC/10Co hard alloy PIM mold filling processes carry out numerical simulation as an example, illustrate of the invention a kind of ultra-fine hard The method for numerical simulation of matter alloy step pole PIM mold filling processes.Specifically implement according to following steps:
1) FEM model is set up:A) model simplification is carried out to step pole, is mold filling entrance with the actual cast gate of die cavity, with Cast gate distal end is exported for mold filling, and step pole 3-D geometric model is set up to die cavity using three-dimensional drawing software UG NX5.0, its It is single side outlet model, shown in such as Fig. 1 (a), derives x_t formatted files;B) file obtained in step a) is imported into ANSYS The softwares of ICEM CFD 13.0, are divided using the tetrahedral grid of non-structural, and global grid size is 0.2mm, wherein, in die cavity Wall, entrance inwall and outlet inside wall are in arc-shaped, after tetrahedral grid is generated, reuse triangular prism mesh refinement arc-shaped edges Edge, through checking mesh quality to reach 0.4, meets and calculates requirement, derives CFX5 formatted files, and carries out network analysis, obtains most Good grid values model;C) file obtained in step b) is imported into FEM-software ANSYS CFX 13.0 and obtains limited Shown in meta-model, such as Fig. 1 (b).
2) set before domain:Respectively name WC/Co compounds, binder mixtures and air be powder, binder and Air, defines the respective parameter of powder, binder and air respectively.Simulation WC/Co compounds are WC/10Co compounds, its WC Powder size is 0.6 μm;Binder mixtures are made up of paraffin, low molecule couplant and high molecular polymer, and each component is constituted And the weight/mass percentage composition of each component is:Wax is hard alloy Wax special, and 63% is accounted for altogether;High molecular polymer is high-density polyethylene Alkene, polypropylene and low density polyethylene (LDPE), account for 30% altogether;Low molecule couplant is stearic acid and o-phthalic acid dibutyl ester, is accounted for altogether 7%.The thermodynamic state of powder is Liquid, and the thermodynamic state of binder is Liquid, and the thermodynamic state of air is Gas, main matter parameter is as shown in table 1.
The WC/10Co of table 1 and binding agent physical parameter
It is theoretical calculation or assumption value;#It is actual measured value;* it is bibliography value.
3) analog type is defined:Selection Unsteady State Simulation, sets total duration as 0.05s, time step are 5 × 10- 5S, initial time are 0s.
4) domain is generated:For step pole creates domain, STEP BAR are named as;Buoyancy model is opened, buoyancy reference density is 1.185g·cm-3;The reference pressure of domain model is 1atm;Buoyancy model is Buoyant, and Y-direction acceleration of gravity is-g, X, Z Direction acceleration of gravity is 0ms-2, buoyancy reference density is set as three density of the smaller phase of phase Midst density, i.e. atmospheric density; Domain is set as static;Mesh free deforms;Multiphase option is set to heterogeneous in fluid simulation, and heat transmission model is set to heat content Can, turbulence model is set to laminar model.In fluid simulation, fluid is to (air | binder) and (air | powder) alternate transmission Free-surface model is, surface tension coefficient is set to 0.072Nm-1, dragging force coefficient is 0.44Pa-1·s-1, without material Transmission;Fluid is mixed model to (binder | powder) alternate transmission, and interface alternation depth is set to 0.2 μm, drag force system Number is 3.6Pa-1·s-1
5) boundary condition is defined:Ultrafine WC/10Co feeding PIM mold filling processes boundary condition is as shown in table 2, wherein by setting It is fixedRespectively 0.49,0.53,0.57,0.61 (correspondenceRespectively 0.51,0.47,0.43,0.39), investigate different powder dress Carrying capacity (Respectively 49%, 53%, 57% and 61%) to the influence of WC/Co feeding mold filling processes, filled with obtaining reasonable powder Carrying capacity.
The PIM mold filling process boundary conditions of table 2
The primary condition of ultrafine WC/10Co feeding PIM mold filling processes is as shown in table 3.
The PIM mold filling process primary condition values of table 3
6) setting solves control:It is 1 to select divalence Euler's formula solving precision backward, convergence that minimum step number is calculated in controlling Step, maximum step number are 100 steps, and convergence scheme is root mean square residual value RMS=1 × 10-4, transient time step is 10 steps.Physics becomes Amount selection mainly has viscosity, pressure, speed, temperature, density, hot-fluid, the volume fraction of binder and powder.
7) the numerical computations file of output suffix entitled def, imports to be simulated defined in CFX-Solver and calculates, using being based on The powder of finite volume method-binding agent multi-phase model, it is assumed that powder particle is to deposit jointly in space optional position with binding agent And the continuous media that can interpenetrate, powder belongs to two kinds of fluids that are independent of one another and interacting with binding agent.
In described multi-phase model, do not undergone phase transition at boundary, two alternate massless are exchanged, and ignore pulsation , meet two-phase current mass, momentum and the energy conservation equation obtained with averaging method, the Reynolds of PIM filling flow processes Number is smaller, can use Nu ≈ 2, and its drag force uses mixed model.
Check problem present in calculating in time by residual sum solution information and/or check the order of accuarcy of solution.
8) the analysis mode results of CFD-Post 13.0 are used.Visual analyzing is carried out to convergent simulation result of calculation, is obtained To in mold filling process the respective VELOCITY DISTRIBUTION of powder, binder and air, Temperature Distribution, pressure distribution, volume fraction distribution, Viscosity profile, influence of the analysis process parameter to mold filling process, optimizes binder formula, determines that the feeding of WC/Co compounds faces Boundary's powder loading.
9) the simulation result of calculation under different operating modes is compared with experimental result, verifies the reasonability of model.
Feeding melt body in the present embodiment in ultrafine WC/10Co feeding mold filling processes on the central plane of cast gate Fraction is distributed and powder temperature changes in distribution figure is as shown in Figure 2.As shown in Figure 2, by the process of touching of filling of the present invention Numerical simulation, can be divided the respective temperature field such as binding agent, powder and air, volume of distribution fraction etc. in mold filling process Analysis.Equally, the mold filling of each phase in feeding mold filling process can be further analyzed by physical fields such as velocity field, viscosity field, density fields Characteristic, further analyzes the producing cause of the defects such as bubble, segregation.Therefore, the present invention is conducive to effectively grasping powder and glues Tie the respective mold filling characteristic of agent, investigate the bubble in ultra-fine cemented carbide feeding mold filling process, the generation of defect such as collapse, for point Analyse process conditions and feeding property, instruct technological parameter and mold design offer useful information.
In the present embodiment during ultrafine WC/10Co feeding mold filling 0.03s on longitudinal centre line binding agent and powder speed difference Distribution map as shown in figure 3, wherein, powder loading is 49%, cast gate for Z=31mm at.Binding agent of the melt at cast gate and The speed difference of powder is big, and with further mold filling, its speed difference reduces, after narrow section is flowed into, the speed of binding agent and powder Increase, its speed difference also increases therewith, and with the further increase of flow distance, its speed difference increases therewith.Therefore mold filling process In, melt flows distance is more long, and the speed of its binding agent and powder is lower, and its speed difference is bigger, and segregation phenomena is more serious, phase point It is bigger from trend.Therefore, when the speed difference near cast gate is close with cast gate, now the powder loading of feeding is critical for its Powder loading, therefore by the numerical simulation of mold filling process of the present invention, it may be determined that ultra-fine cemented carbide WC/10Co's Critical powder loading.
The present embodiment can with analysed for powder useful load to binding agent in ultrafine WC/10Co hard alloy PIM mold filling processes with The influence that powder is distributed along cast gate direction volume fraction, as shown in Figure 4 and Figure 5, wherein, X=2.8mm is at cast gate.It can be seen that, no During with powder loading, the volume fraction distribution of binding agent and powder is essentially identical, whenWhen, binding agent and powder divide Cloth is most stable, i.e., the reasonable useful load of ultrafine WC/10Co feedings is 53% or so.
The reasonable useful load of the WC/10Co feedings that the present invention is obtained is 53%, consistent with experimental result, can be with by Fig. 6 Obtain when useful load is 53%, WC-10Co alloys combination property is optimal, therefore, method for numerical simulation of the invention rationally, can Root and its influence factor are produced with the segregation for effectively analyzing mold filling process, is analysis process condition and feeding property, instructed work Skill parameter and mold design offer useful information.

Claims (11)

1. a kind of method for numerical simulation of ultra-fine cemented carbide step pole PIM mold filling processes, it is characterised in that including following step Suddenly:
1) model simplification is carried out to step pole, setting mold filling entrance is exported with mold filling, sets up step pole 3-D geometric model;
2) to step 1) the step pole 3-D geometric model carries out mesh generation, sets up FEM model;
3) to step 2) FEM model carries out physical definition, according to the operation ring of live ultra-fine cemented carbide injection moulding Border and do not influence calculate accuracy in the case of, gas-liquid-solid multiphase flow filling flow process in die cavity is assumed and letter Change, specific setting is as follows:
A () defines multithread phase material:Respectively name WC/Co compounds, binder mixtures and air be powder, binder and Air, defines the respective parameter of powder, binder and air respectively;
B () defines analog type:Selection Unsteady State Simulation, setting time parameter;
C () defines heterogeneous fluid domain:For step pole creates domain, fluid model and fluid details are defined;
D () defines boundary condition:Perimeter strip including mold filling entrance (inlet), mold filling outlet (outlet) and die wall (wall) Part, provides specific boundary condition respectively;Setting initial value;
E () setting solves control:Select divalence Euler's formula solving precision backward;
4) numerical simulation calculation:Solved using finite volume method, and by residual sum solve information check in time calculating in The problem of presence and/or check the order of accuarcy of solution;
5) visual analyzing is carried out to convergent simulation result of calculation, powder, binder and air be each in obtaining mold filling process VELOCITY DISTRIBUTION, Temperature Distribution, pressure distribution, volume fraction distribution, viscosity profile, shadow of the analysis process parameter to mold filling process The critical powder loading of feeding for ring, optimizing binder formula, determine WC/Co compounds.
2. method according to claim 1, it is characterised in that step 1) in, it is mold filling entrance with the actual cast gate of die cavity, with Cast gate distal end exports for mold filling.
3. method according to claim 1, it is characterised in that step 2) in divided using the tetrahedral grid of non-structural, Global grid size is 0.2mm, wherein, mould intracavity wall, mold filling entrance inwall and mold filling outlet inside wall are in arc-shaped, in generation four After the volume mesh of face, triangular prism mesh refinement arc edge is reused, through checking mesh quality to reach 0.4, meet and calculate requirement.
4. method according to claim 1, it is characterised in that step 3) in (b), set total duration as 0.05s, when Spacer step a length of 5 × 10-5S, initial time are 0s.
5. method according to claim 1, it is characterised in that step 3) it is that step pole creates domain in (c), it is named as STEP BAR;Buoyancy model is opened, buoyancy reference density is 1.185gcm-3;The reference pressure of domain model is 1atm;Buoyancy mould Type is Buoyant, and Y-direction acceleration of gravity is-g, and X, Z-direction acceleration of gravity are 0ms-2, buoyancy reference density is set as Three density of the smaller phase of phase Midst density, i.e. atmospheric density;Domain is set as static;Mesh free deforms.
6. method according to claim 1, it is characterised in that step 3) in (c), multiphase option is set in fluid simulation Heterogeneous, heat transmission model is set to heat content energy, and turbulence model is set to laminar model.
7. method according to claim 1, it is characterised in that step 3) in (c), in fluid simulation fluid to (air | Binder) and (air | powder) alternate transmission is Free-surface model, surface tension coefficient is set to 0.072Nm-1, drag Drag coefficient is 0.44Pa-1·s-1, without mass transfer;Fluid is mixed model, boundary to (binder | powder) alternate transmission Face interaction depth is set to 0.2 μm~0.6 μm, and dragging force coefficient is 0.44Pa-1·s-1~14.4Pa-1·s-1
8. method according to claim 1, it is characterised in that step 3) in (d), the perimeter strip of mold filling entrance (inlet) Part is to set fluid as subsonic speed, and quality and momentum are set as 0~20ms of standard speed-1, heat transmission is set as static warm Degree 423K, the volume fraction of powder, binder and air is respectively in fluid valueWherein,The perimeter strip of mold filling outlet (outlet) Part is to set fluid as subsonic speed, and quality and momentum are set as averaged static pressure, and relative pressure is 0Pa, and hybrid cytokine is 0.05;Die wall (Wall) boundary condition is set as that, without sliding, heat transmission temperature is 298K.
9. method according to claim 1, it is characterised in that step 3) in (d), initial value setting:The given t=0 moment The speed of the temperature T=298K in die cavity, pressure P=1atm, powder, binder and air is vp=vb=va=0.0001m/ The volume fraction of s, airThe volume fraction of powder and binder is
10. method according to claim 1, it is characterised in that step 3) in (e), minimum step number is calculated in convergence control For 1 step, maximum step number are 100 steps, convergence scheme is root mean square residual value RMS=1 × 10-4, transient time step is 10 steps.
11. methods according to claim 1, it is characterised in that step 4) in, numerical simulation is using based on finite volume method Powder-binding agent multi-phase model, it is assumed that powder particle and binding agent are exist jointly and can phase in space optional position The continuous media for mutually permeating, powder belongs to two kinds of fluids that are independent of one another and interacting with binding agent.
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