CN109992885A - A kind of casting limited fatigue life member prediction technique and system - Google Patents
A kind of casting limited fatigue life member prediction technique and system Download PDFInfo
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
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Abstract
The invention discloses a kind of casting limited fatigue life member prediction technique and systems, the prediction technique, first, establish the casting process model of casting, and mold filling pressure, mold filling temperature, mold temperature and heat transfer coefficient are applied to the casting process model, casting process is simulated, microdefect data are obtained；Then, the microdefect data are mapped on the finite element model using grid data pass-algorithm, establish the finite element model comprising microdefect and the SN curve comprising microdefect；Finally, applying load using the finite element model comprising microdefect, finite element modelling is carried out, and predict the fatigue life of casting according to the SN curve comprising microdefect.The present invention is during the fatigue life prediction of the mean stress using macroscopic view, it is contemplated that the influence of the microdefects such as shrinkage cavity, secondary dendrite improves the accuracy of casting fatigue life prediction.
Description
Technical field
The present invention relates to engineering component fatigue life prediction field, in particular to a kind of casting limited fatigue life member prediction
Method and system.
Background technique
In practice production, most of engineering components all subject the effect of various load, in order to obtain the use of part
Service life, scholars usually predict fatigue life using the method for establishing finite element model.However part is in production process
In can generate a series of defect, especially in casting process, casting can generate Models For Secondary Dendrite Arm spacing, and Shrinkage cavity etc. is micro-
Defect is seen, simulates casting process by softwares such as ProCAST, defect and its position, size for be likely to occur to casting etc. carry out
Prediction, these microdefects have a certain impact to the fatigue life of part.All the time, traditional Prediction method for fatigue life
Although that the consideration of the data characteristicses such as geometry, load is more comprehensive, casting microdefect is had ignored to the shadow of fatigue life
It rings, leading to prediction result, there are deviations.
Summary of the invention
The object of the present invention is to provide a kind of casting limited fatigue life member prediction technique and systems, using the flat of macroscopic view
During the fatigue life prediction of equal stress, it is contemplated that the influence of the microdefects such as shrinkage cavity, secondary dendrite, to improve casting fatigue
The accuracy of life prediction.
To achieve the above object, the present invention provides following schemes:
A kind of casting limited fatigue life member prediction technique, the prediction technique include the following steps:
Establish the casting process model of casting；
Mold filling pressure, mold filling temperature, mold temperature and heat transfer coefficient are applied to the casting process model, simulation was cast
Journey obtains microdefect data；The microdefect data include shrinkage cavity data and secondary dendrite data；
Establish finite element model；
The microdefect data are mapped on the finite element model using grid data pass-algorithm, foundation includes
The finite element model of microdefect, and establish the SN curve comprising microdefect；
Load is applied to the finite element model comprising microdefect according to actual condition, finite element modelling is carried out, obtains
Obtain finite element modelling result；
According to the finite element modelling result and the SN curve comprising microdefect, the fatigue life of casting is carried out
Prediction.
Optionally, described that the microdefect data are mapped to by the finite element model using grid data pass-algorithm
On, the finite element model comprising microdefect is established, and establish the SN curve comprising microdefect, specifically included:
The microdefect data are mapped on the finite element model using grid data pass-algorithm, described in acquisition
The microdefect data put on finite element model；
According to the microdefect data put on the finite element model, the bullet of each unit in the finite element model is calculated
Property modulus；
The elasticity modulus of each unit is added in the finite element model, the finite element mould comprising microdefect is obtained
Type；
According to the microdefect data put on the finite element model, the SN curve comprising microdefect is established.
Optionally, described that the microdefect data are mapped to by the finite element model using grid data pass-algorithm
On, the microdefect data put on the finite element model are obtained, are specifically included:
Obtain the tetrahedron element comprising point P (x, y, z) on finite element model on casting process model, the tetrahedron list
The first node of member, second node, third node and fourth node coordinate be respectively as follows: (x1, y1, z1), (x2, y2, z3), (x3,
y3, z3), (x4, y4, z4)；
Utilize formulaCalculate finite element model on point P, second node, third node and
The tetrahedral volume of fourth node composition, obtains the first volume；
Utilize formulaCalculate finite element model on point P, first node, third node and
The tetrahedral volume of fourth node composition, obtains the second volume；
Utilize formulaCalculate finite element model on point P, first node, second node and
The tetrahedral volume of fourth node composition, obtains third volume；
Utilize formulaCalculate finite element model on point P, first node, second node and
The tetrahedral volume of third node composition, obtain fourth volume；
According to first volume, second volume, the third volume and the fourth volume, formula is utilizedCalculate the natural coordinates component (L of the tetrahedron element1, L2, L3, L4)；
Difference value equation λ is utilized according to the natural coordinates componentP=L1λ1+L2λ2+L3λ3+L4λ4, calculate on finite element model
The secondary dendrite length lambda of point P (x, y, z)P, wherein λ1、λ2、λ3And λ4The respectively first node of tetrahedron element, the second section
The secondary dendrite length of point, third node and fourth node；
Difference value equation Φ is utilized according to the natural coordinates componentP=L1Φ1+L2Φ2+L3Φ3+L4Φ4, calculate finite element
The contraction cavity ratio Φ of point P (x, y, z) on modelP, wherein Φ1、Φ2、Φ3And Φ4The respectively first node of tetrahedron element,
The contraction cavity ratio of two nodes, third node and fourth node；
Utilize formula Φi=(Φi1+Φi2+Φi3+Φi4)/4 calculate i-th comprising point P in the finite element model
The average value of each node contraction cavity ratio of unit, obtains the contraction cavity ratio Φ of i-th of uniti；Φi1, Φi2, Φi3And Φi4I-th of unit
Four nodes contraction cavity ratio；
According to the contraction cavity ratio Φ of i-th of uniti, utilize formulaIt calculates i-th on finite element model
The shrinkage cavity area area of a uniti, wherein ViFor the unit volume of i-th of unit of finite element model.
Optionally, it according to the microdefect data put on the finite element model, calculates each in the finite element model
The elasticity modulus of unit, specifically includes:
According to the contraction cavity ratio Φ of i-th of uniti, utilize formula EΦ=E0(1-Φi), calculate the springform of i-th of unit
Amount；Wherein, E0For the elasticity modulus of zero defect ideal material.
Optionally, described according to the microdefect data put on the finite element model, establish the SN comprising microdefect
Curve specifically includes:
According to the microdefect data put on the finite element model, formula is utilized
Calculate fatigue strength σ caused by microdefectD, wherein A, B, C and D are respectively the first relevant parameter, the second relevant parameter,
Three relevant parameters and the 4th relevant parameter；
The fatigue strength σ according to caused by microdefectD, establish the mathematical model of the relationship of mean stress and fatigue limit: Sa
=(1-R) Sm/ (1+R), wherein R is stress ratio,SmFor mean stress, SaFor mean stress
SmUnder fatigue limit, SuFor the breaking strength of material；
According to the mathematical model of mean stress and the relationship of fatigue limit, determine that the SN comprising microdefect of each node is bent
Line, SnN=C, whereinC=Su n。
A kind of casting limited fatigue life member forecasting system, the forecasting system include:
Casting process model building module, for establishing the casting process model of casting；
Microdefect data acquisition module, for applying mold filling pressure, mold filling temperature, mold to the casting process model
Temperature and heat transfer coefficient simulate casting process, obtain microdefect data；The microdefect data include shrinkage cavity data and two
Secondary dendrite data；
Finite element model establishes module, for establishing finite element model；
Mapping block, for the microdefect data to be mapped to the finite element mould using grid data pass-algorithm
In type, the finite element model comprising microdefect is established, and establish the SN curve comprising microdefect；
Finite element modelling module is carried for being applied according to actual condition to the finite element model comprising microdefect
Lotus carries out finite element modelling, obtains finite element modelling result；
Fatigue life prediction module, for bent according to the finite element modelling result and the SN comprising microdefect
Line predicts the fatigue life of casting.
Optionally, the mapping block, specifically includes:
Mapping submodule, for the microdefect data to be mapped to the finite element using grid data pass-algorithm
On model, the microdefect data put on the finite element model are obtained；
Elasticity modulus computational submodule, for according to the microdefect data put on the finite element model, described in calculating
The elasticity modulus of each unit in finite element model；
Finite element model setting up submodule comprising microdefect, it is described for the elasticity modulus of each unit to be added to
In finite element model, the finite element model comprising microdefect is obtained；
SN curve setting up submodule comprising microdefect, for according to the microdefect number put on the finite element model
According to foundation includes the SN curve of microdefect.
Optionally, the mapping submodule, specifically includes:
Tetrahedron element acquiring unit, for obtaining on casting process model comprising point P (x, y, z) on finite element model
Tetrahedron element, the first node of the tetrahedron element, second node, third node and fourth node coordinate be respectively as follows:
(x1, y1, z1), (x2, y2, z3), (x3, y3, z3), (x4, y4, z4)；
First volume computing unit, for utilizing formulaCalculate point on finite element model
P, the tetrahedral volume of second node, third node and fourth node composition, obtains the first volume；
Second volume computing unit, for utilizing formulaCalculate point on finite element model
P, the tetrahedral volume of first node, third node and fourth node composition, obtains the second volume；
Third volume computing unit, for utilizing formulaCalculate point on finite element model
P, the tetrahedral volume of first node, second node and fourth node composition, obtains third volume；
Fourth volume computing unit, for utilizing formulaCalculate finite element model on point P,
The tetrahedral volume of first node, second node and third node composition, obtain fourth volume；
Natural coordinates component calculation unit, for according to first volume, second volume, the third volume and
The fourth volume, utilizes formulaCalculate the natural coordinates component (L of the tetrahedron element1, L2, L3,
L4)；
Difference value equation λ is utilized according to the natural coordinates componentP=L1λ1+L2λ2+L3λ3+L4λ4, calculate on finite element model
The secondary dendrite length lambda of point P (x, y, z)P, wherein λ1、λ2、λ3And λ4The respectively first node of tetrahedron element, the second section
The secondary dendrite length of point, third node and fourth node；
Difference value equation Φ is utilized according to the natural coordinates componentP=L1Φ1+L2Φ2+L3Φ3+L4Φ4, calculate finite element
The contraction cavity ratio Φ of point P (x, y, z) on modelP, wherein Φ1、Φ2、Φ3And Φ4The respectively first node of tetrahedron element,
The contraction cavity ratio of two nodes, third node and fourth node；
Utilize formula Φi=(Φi1+Φi2+Φi3+Φi4)/4 calculate i-th comprising point P in the finite element model
The average value of each node contraction cavity ratio of unit, obtains the contraction cavity ratio Φ of i-th of uniti；Φi1, Φi2, Φi3And Φi4I-th of unit
Four nodes contraction cavity ratio；
According to the contraction cavity ratio Φ of i-th of uniti, utilize formulaIt calculates i-th on finite element model
The shrinkage cavity area area of a uniti, wherein ViFor the unit volume of i-th of unit of finite element model.
Optionally, the elasticity modulus computational submodule, specifically includes:
Elasticity modulus computing unit, for the contraction cavity ratio Φ according to i-th of uniti, utilize formula EΦ=E0(1-Φi), meter
Calculate the elasticity modulus of i-th of unit；Wherein, E0For the elasticity modulus of zero defect ideal material.
Optionally, the SN curve setting up submodule comprising microdefect, specifically includes:
Calculation of Fatigue Strength unit caused by microdefect, for according to the microdefect number put on the finite element model
According to utilizing formulaMicrodefect is calculated to cause
Fatigue strength σD, wherein A, B, C and D are respectively the first relevant parameter, the second relevant parameter, third relevant parameter and the 4th
Relevant parameter；
The mathematical model of the relationship of mean stress and fatigue limit establishes unit, is used for the fatigue according to caused by microdefect
Intensity σD, establish the mathematical model of the relationship of mean stress and fatigue limit: Sa=(1-R) Sm/ (1+R), wherein R is stress
Than,SmFor mean stress, SaFor mean stress SmUnder fatigue limit, SuFor the fracture of material
Intensity；
SN curve determining unit determines each node for the mathematical model according to mean stress and the relationship of fatigue limit
The SN curve comprising microdefect, SnN=C, whereinC=Su n。
The specific embodiment provided according to the present invention, the invention discloses following technical effects:
The invention discloses a kind of casting limited fatigue life member prediction technique and system, the prediction techniques, firstly, building
The casting process model of vertical casting, and mold filling pressure, mold filling temperature, mold temperature and heat transfer are applied to the casting process model
Coefficient simulates casting process, obtains microdefect data；Then, using grid data pass-algorithm by the microdefect number
According to being mapped on the finite element model, the finite element model comprising microdefect and the SN curve comprising microdefect are established；
Finally, applying load using the finite element model comprising microdefect, finite element modelling is carried out, and according to including microdefect
SN curve predicts the fatigue life of casting.Fatigue life prediction process of the present invention in the mean stress using macroscopic view
In, it is contemplated that the influence of the microdefects such as shrinkage cavity, secondary dendrite improves the accuracy of casting fatigue life prediction.
Detailed description of the invention
It in order to more clearly explain the embodiment of the invention or the technical proposal in the existing technology, below will be to institute in embodiment
Attached drawing to be used is needed to be briefly described, it should be apparent that, the accompanying drawings in the following description is only some implementations of the invention
Example, for those of ordinary skill in the art, without any creative labor, can also be according to these attached drawings
Obtain other attached drawings.
Fig. 1 is a kind of flow chart of casting limited fatigue life member prediction technique provided by the invention；
Fig. 2 is a kind of process of the preferred embodiment of casting limited fatigue life member prediction technique provided by the invention
Figure；
Fig. 3 is wedge block model schematic provided by the invention；
Fig. 4 is the structural schematic diagram of the tetrahedron element of casting process model provided by the invention；
Fig. 5 is a kind of structure chart of casting limited fatigue life member forecasting system provided by the invention.
Specific embodiment
The object of the present invention is to provide a kind of casting limited fatigue life member prediction technique and systems, using the flat of macroscopic view
During the fatigue life prediction of equal stress, it is contemplated that the influence of the microdefects such as shrinkage cavity, secondary dendrite, to improve casting fatigue
The accuracy of life prediction.
In order to make the foregoing objectives, features and advantages of the present invention clearer and more comprehensible, with reference to the accompanying drawing and specific real
Mode is applied to be described in further detail invention.
Embodiment 1
The embodiment of the present invention 1 provides a kind of casting limited fatigue life member prediction technique.
As shown in Figure 1, the prediction technique includes the following steps:
Step 101, the casting process model of casting is established；Specifically, it is soft that casting and casting mould are imported into ProCAST
In part, grid dividing is carried out to casting and mold using tetrahedron element and exports corresponding casting gridding information.
Step 102, mold filling pressure, mold filling temperature, mold temperature and heat transfer coefficient, mould are applied to the casting process model
Quasi- casting process, obtains microdefect data；The microdefect data include shrinkage cavity data and secondary dendrite data.
Step 103, finite element model is established.
Step 104, the microdefect data are mapped on the finite element model using grid data pass-algorithm,
The finite element model comprising microdefect is established, and establishes the SN curve comprising microdefect；In Abaqus finite element model
The cell node of cell node and ProCAST casting process model is not correspondingly, to obtain Abaqus finite element mould
Shrinkage cavity discrete on casting and secondary dendrite length data are mapped to by the gusset material attribute in type using shape function method
On Abaqus model.Casting is typical 4 node tetrahedron element in ProCAST software, for Abaqus stress prediction mould
Any one node P (x, y, z) in type first has to search the unit e for completely including this point, and interior joint 1,2,3 and 4 is unit e
Local nodes number, λ1, λ2, λ3, λ4For the secondary dendrite length of each node of ProCAST grid cell, λpIt is to be asked for node P
Secondary dendrite length.
Specifically, the tetrahedron element comprising point P (x, y, z) on finite element model on casting process model is obtained, it is described
The first node of tetrahedron element, second node, third node and fourth node coordinate be respectively as follows: (x1, y1, z1), (x2, y2,
z3), (x3, y3, z3), (x4, y4, z4)。
Utilize formulaCalculate the volume of the tetrahedron element；Utilize formulaCalculate the four of point P on finite element model, second node, third node and fourth node composition
The volume of face body obtains the first volume；Utilize formulaCalculate point P, first on finite element model
The tetrahedral volume of node, third node and fourth node composition, obtains the second volume；Utilize formulaCalculate the four of point P on finite element model, first node, second node and fourth node composition
The volume of face body, obtains third volume；Utilize formulaCalculate point P, first on finite element model
The tetrahedral volume of node, second node and third node composition, obtain fourth volume.When the first volume, the second volume,
Have in third volume and fourth volume one for negative value when, then it is assumed that the tetrahedron element does not include point P.
According to first volume, second volume, the third volume and the fourth volume, formula is utilizedCalculate the natural coordinates component (L of the tetrahedron element1, L2, L3, L4)。
Difference value equation λ is utilized according to the natural coordinates componentP=L1λ1+L2λ2+L3λ3+L4λ4, calculate on finite element model
The secondary dendrite length lambda of point P (x, y, z)P, wherein λ1、λ2、λ3And λ4The respectively first node of tetrahedron element, the second section
The secondary dendrite length of point, third node and fourth node；Difference value equation Φ is utilized according to the natural coordinates componentP=L1Φ1
+L2Φ2+L3Φ3+L4Φ4, calculate the contraction cavity ratio Φ of point P (x, y, z) on finite element modelP, wherein Φ1、Φ2、Φ3And Φ4Point
Not Wei the first node of tetrahedron element, second node, third node and fourth node contraction cavity ratio；Utilize formula Φi=
(Φi1+Φi2+Φi3+Φi4)/4 calculate being averaged for each node contraction cavity ratio of i-th of unit in the finite element model comprising point P
Value, obtains the contraction cavity ratio Φ of i-th of uniti；Φi1, Φi2, Φi3And Φi4The contraction cavity ratio of four nodes of i-th of unit；According to
The contraction cavity ratio Φ of i-th of uniti, utilize formulaCalculate the shrinkage cavity of i-th of unit on finite element model
Area areai, wherein ViFor the unit volume of i-th of unit of finite element model.It is write according to grid data pass-algorithm
Fortran conversion program, it is defeated by the microdefect information read in ProCAST and Abaqus model meshes information read-in programme
The microdefect of Abaqus model node out.
According to the microdefect data put on the finite element model, formula is utilized
Calculate fatigue strength σ caused by microdefectD, wherein A, B, C and D are respectively the first relevant parameter, the second relevant parameter,
Three relevant parameters and the 4th relevant parameter；Fatigue strength σDIt is material 106Fatigue stress amplitude under secondary circulation, material it is tired
Labor intensity is related with the secondary dendrite of material and shrinkage cavity area, it is assumed that fatigue limit σ when R=-1DWith the relationship of microdefect are as follows:A, B, C, D are to have with material and load type
The parameter of pass.
The fatigue strength σ according to caused by microdefectD, establish the mathematical model of the relationship of mean stress and fatigue limit: Sa
=(1-R) Sm/ (1+R), wherein R is stress ratio,SmFor mean stress, SaFor mean stress
SmUnder fatigue limit, SuFor the breaking strength of material；According to the mathematical model of mean stress and the relationship of fatigue limit, determine
The SN curve comprising microdefect of each node, SnN=C, whereinC=Su n；Specifically,
The mean stress of material equally has larger impact to its service life, and Goodman gives equivalent life curve, calculation formula are as follows:Wherein, S-1The fatigue limit of material, i.e. S when for stress ratio R=-1-1=σD, SuFor the breaking strength of material,
SaIt is 10 to work as fatigue life6When stress amplitude, it may also be said to, SaFor in mean stress SmUnder fatigue limit.
Stress ratio R and mean stress SmRelationship are as follows:
Sm=(1+R) Sa/(1-R)；
I.e.
In conclusion mean stress SmWith fatigue limit SaRelationship are as follows:
Sa=(1-R) Sm/(1+R)。
According to the mathematical model of mean stress and the relationship of fatigue limit, determine that the SN comprising microdefect of each node is bent
Line, SnN=C, by two o'clock (Sa,106) and (Su, 1) and the formula of bringing into obtains:
C=Su n。
According to the microdefect data put on the finite element model, the bullet of each unit in the finite element model is calculated
Property modulus；The elasticity modulus of each unit is added in the finite element model, the finite element mould comprising microdefect is obtained
Type；Specifically, considering the variation of contraction cavity ratio to elasticity modulus by the contraction cavity ratio according to node each in Abaqus finite element model
It influences, to each building unit elasticity modulus in Abaqus finite element analysis model, the contraction cavity ratio of unit takes the unit respectively to save
The average value of point contraction cavity ratio: Φi=(Φi1+Φi2+Φi3+Φi4)/4；Calculate the elastic modulus E of i-th of uniti=E0(1-
Φi)；Wherein, E0For the elasticity modulus of zero defect ideal material.
Abaqus finite element model each unit elasticity modulus is read in Abaqus model, establishes having comprising microdefect
Limit meta-model.
Step 105, load is applied to the finite element model comprising microdefect according to actual condition, carries out finite element
Simulation obtains finite element modelling result.
Step 106, according to the finite element modelling result and the SN curve comprising microdefect, to the fatigue of casting
Service life is predicted.
Embodiment 2
The embodiment of the present invention 2 provides an a kind of preferred embodiment party of casting limited fatigue life member prediction technique
Formula, but implementation of the invention is not limited to embodiment defined by the embodiment of the present invention 2.
As shown in Fig. 2, Prediction method for fatigue life of the invention includes three modules: ProCAST module, Abaqus module
And FE-SAFE module, concrete operations are as follows:
(1) gridding information, secondary dendrite, shrinkage cavity area and the contraction cavity ratio of casting are obtained by ProCAST casting process simulation；
(2) by ProCAST gridding information, secondary dendrite data, shrinkage cavity area, contraction cavity ratio data and Abaqus gridding information
Grid data transmission procedure is read in, Abaqus model node material properties are obtained；
(3) Abaqus model node material properties are read in into mathematical model program, obtains the bullet of Abaqus model each unit
The S-N curve of property modulus and each node of Abaqus model；
(4) elasticity modulus of Abaqus model each unit is imported into Abaqus model to be calculated, applies load, carried out
Finite element modelling；
(5) the S-N curve of each node of Abaqus model and Abaqus results model odb file are imported into FE-SAFE,
Carry out fatigue life prediction.
Below in conjunction with specific embodiment, step (1)-(5) are explained.
In order to verify the correctness of the above method, aluminium alloy casting pattern shown in Fig. 3 is established, casting is a wedge block
Body, wherein 1 is wedge block mold, and 2 be wedge block, and 3 be die casting mouth, and 4 be cylindrical tensile specimen.It is different high from wedge block
Degree position cuts out cylindrical tensile specimen, since different height position has different cooling velocities in casting process, therefore is cut
Cylindrical tensile specimen out has different micro-datas, and the method proposed through the invention cuts out different height position
Cylindrical tensile specimen carries out life prediction, analyzes influence of the more different micro-datas to the service life.
Step (1): wedge block casting and casting mould are imported into ProCAST software, using C3D4 tetrahedron element
Grid dividing is carried out to casting and mold, and exports the gridding information of casting, setting mold filling pressure, speed, mold temperature and biography
The parameters such as hot coefficient, simulate casting process, obtain the defective data of secondary dendrite, shrinkage cavity area and contraction cavity ratio；
Step (2): Fig. 4 is a typical 4 node tetrahedron element.Its interior joint 1,2,3 and 4 is the part of unit e
Node serial number, node P (x, y, z) are the node of cylindrical tensile specimen in Abaqus.The coordinate value of local nodes 1,2,3 and 4
(x1, y1, z1), (x2, y2, z3), (x3, y3, z3), (x4, y4, z4) can be read from ProCAST software, it is passed by grid data
Program is passed, by ProCAST gridding information obtained in step (1), secondary dendrite, shrinkage cavity area, contraction cavity ratio and Abaqus cylinder
Tensile test specimen gridding information read-in programme obtains the defective data of each node of Abaqus cylindrical tensile specimen model；
Step (3): the defective data for each node of Abaqus cylindrical tensile specimen model that step (2) is obtained reads in mathematics
Model program, and the breaking strength S of definition materialu=325, mean stress Sm=0, stress ratio R=-1, basis material springform
Measure Eu=70000, the elasticity modulus of Abaqus cylindrical tensile specimen model each unit and the S-N curve of each node are obtained, due to
The microdefect of each node is there are deviation, and there are deviations for the S-N curve and elasticity modulus that lead to each node；
Step (4): Abaqus cylindrical tensile specimen model each unit elasticity modulus obtained in step (3) is imported into
In Abaqus finite element model, and applies unidirectional load and carry out force analysis；
Step (5): by the results model odb file that step (4) obtains and the SN curve belt for each node that step (3) obtains
Enter and carry out life prediction into FE-SAFE software, obtains tensile test specimen life prediction result；
By the above method, fatigue life prediction is carried out to the cylindrical tensile specimen of different height respectively.
By comparison, it was found that secondary dendrite is gradually increased, and contraction cavity ratio is also gradually increased with the raising of wedge height,
The cylindrical tensile specimen service life of corresponding height is gradually reduced, and is consistent with the effect tendency of actual casting defect, and its tired longevity
It orders closer to experimental result, improves precision of prediction.
Embodiment 3
The embodiment of the present invention 3 provides a kind of casting limited fatigue life member forecasting system.
As shown in figure 5, the forecasting system includes:
Casting process model building module 501, for establishing the casting process model of casting；
Microdefect data acquisition module 502, for the casting process model apply mold filling pressure, mold filling temperature,
Mold temperature and heat transfer coefficient simulate casting process, obtain microdefect data；The microdefect data include shrinkage cavity data
With secondary dendrite data；
Finite element model establishes module 503, for establishing finite element model；
Mapping block 504, it is described limited for being mapped to the microdefect data using grid data pass-algorithm
On meta-model, the finite element model comprising microdefect is established, and establish the SN curve comprising microdefect；The mapping block
504, it specifically includes: mapping submodule, it is described for being mapped to the microdefect data using grid data pass-algorithm
On finite element model, the microdefect data put on the finite element model are obtained；Elasticity modulus computational submodule is used for basis
The microdefect data put on the finite element model, calculate the elasticity modulus of each unit in the finite element model；Include
The finite element model setting up submodule of microdefect, for the elasticity modulus of each unit to be added to the finite element model
In, obtain the finite element model comprising microdefect；SN curve setting up submodule comprising microdefect, for having according to
The microdefect data put on limit meta-model, establish the SN curve comprising microdefect.
Finite element modelling module 505, for being applied according to actual condition to the finite element model comprising microdefect
Load carries out finite element modelling, obtains finite element modelling result；
Fatigue life prediction module 506, for according to the finite element modelling result and the SN comprising microdefect
Curve predicts the fatigue life of casting.
Wherein, the mapping submodule, specifically includes: tetrahedron element acquiring unit, for obtaining casting process model
The upper tetrahedron element comprising point P (x, y, z) on finite element model, the first node of the tetrahedron element, second node, the
Three nodes and the coordinate of fourth node are respectively as follows: (x1, y1, z1), (x2, y2, z3), (x3, y3, z3), (x4, y4, z4)；First volume
Computing unit, for utilizing formulaCalculate point P, second node, third section on finite element model
The tetrahedral volume of point and fourth node composition, obtains the first volume；Second volume computing unit, for utilizing formulaCalculate the four of point P on finite element model, first node, third node and fourth node composition
The volume of face body obtains the second volume；Third volume computing unit, for utilizing formulaMeter
The tetrahedral volume for calculating point P on finite element model, first node, second node and fourth node composition, obtains third volume；
Fourth volume computing unit, for utilizing formulaCalculate point P, first segment on finite element model
The tetrahedral volume of point, second node and third node composition, obtain fourth volume；Natural coordinates component calculation unit is used
According to first volume, second volume, the third volume and the fourth volume, formula is utilizedCalculate the natural coordinates component (L of the tetrahedron element1, L2, L3, L4)；According to the natural coordinates component
Utilize difference value equation λP=L1λ1+L2λ2+L3λ3+L4λ4, calculate the secondary dendrite length lambda of point P (x, y, z) on finite element modelP,
Wherein, λ1、λ2、λ3And λ4Respectively the first node of tetrahedron element, second node, third node and fourth node is secondary
Dendrite length；Difference value equation Φ is utilized according to the natural coordinates componentP=L1Φ1+L2Φ2+L3Φ3+L4Φ4, calculate finite element
The contraction cavity ratio Φ of point P (x, y, z) on modelP, wherein Φ1、Φ2、Φ3And Φ4The respectively first node of tetrahedron element,
The contraction cavity ratio of two nodes, third node and fourth node；Utilize formula Φi=(Φi1+Φi2+Φi3+Φi4)/4, described in calculating
The average value of each node contraction cavity ratio of i-th of unit in finite element model comprising point P, obtains the contraction cavity ratio Φ of i-th of uniti；
Φi1, Φi2, Φi3And Φi4The contraction cavity ratio of four nodes of i-th of unit；According to the contraction cavity ratio Φ of i-th of uniti, utilize public affairs
FormulaCalculate the shrinkage cavity area area of i-th of unit on finite element modeli, wherein ViFor finite element mould
The unit volume of i-th of unit of type.
The elasticity modulus computational submodule, specifically includes: elasticity modulus computing unit, for according to i-th unit
Contraction cavity ratio Φi, utilize formula EΦ=E0(1-Φi), calculate the elasticity modulus of i-th of unit；Wherein, E0For zero defect ideal material
The elasticity modulus of material
The SN curve setting up submodule comprising microdefect, specifically includes: fatigue meter caused by microdefect
Unit is calculated, for utilizing formula according to the microdefect data put on the finite element modelCalculate fatigue strength caused by microdefect
σD, wherein A, B, C and D are respectively the first relevant parameter, the second relevant parameter, third relevant parameter and the 4th relevant parameter；It is flat
The mathematical model of the relationship of equal stress and fatigue limit establishes unit, is used for the fatigue strength σ according to caused by microdefectD, build
The mathematical model of the relationship of vertical mean stress and fatigue limit: Sa=(1-R) Sm/ (1+R), wherein R is stress ratio,SmFor mean stress, SaFor mean stress SmUnder fatigue limit, SuIt is strong for the fracture of material
Degree；SN curve determining unit, for the mathematical model according to mean stress and the relationship of fatigue limit, determine each node includes
The SN curve of microdefect, SnN=C, whereinC=Su n。
The present invention has fully considered that microcosmic casting flaw and macroscopic view are average on the basis of traditional Prediction method for fatigue life
Influence of the stress to fatigue life, defect and its position, size for be likely to occur to casting etc. are predicted, pass through mathematical model
Microscopic feature data are converted to the influence of mechanical property, while considering influence of the mean stress to fatigue life, are established
Macro microcosmic united fatigue life prediction model, improves the precision of life prediction.
Each embodiment in this specification is described in a progressive manner, the highlights of each of the examples are with other
The difference of embodiment, the same or similar parts in each embodiment may refer to each other.For system disclosed in embodiment
For, since it is corresponded to the methods disclosed in the examples, so being described relatively simple, related place is said referring to method part
It is bright.
Specific examples are used herein to describe the principles and implementation manners of the present invention, the explanation of above embodiments
Method and its core concept of the invention are merely used to help understand, described embodiment is only that a part of the invention is real
Example is applied, instead of all the embodiments, based on the embodiments of the present invention, those of ordinary skill in the art are not making creation
Property labour under the premise of every other embodiment obtained, shall fall within the protection scope of the present invention.
Claims (10)
1. a kind of casting limited fatigue life member prediction technique, which is characterized in that the prediction technique includes the following steps:
Establish the casting process model of casting；
Mold filling pressure, mold filling temperature, mold temperature and heat transfer coefficient are applied to the casting process model, simulate casting process,
Obtain microdefect data；The microdefect data include shrinkage cavity data and secondary dendrite data；
Establish finite element model；
The microdefect data are mapped on the finite element model using grid data pass-algorithm, are established comprising microcosmic
The finite element model of defect, and establish the SN curve comprising microdefect；
Load is applied to the finite element model comprising microdefect according to actual condition, finite element modelling is carried out, is had
Limit first analog result；
According to the finite element modelling result and the SN curve comprising microdefect, the fatigue life of casting is carried out pre-
It surveys.
2. casting limited fatigue life member prediction technique according to claim 1, which is characterized in that described to use grid number
The microdefect data are mapped on the finite element model according to pass-algorithm, establish the finite element mould comprising microdefect
Type, and the SN curve comprising microdefect is established, it specifically includes:
The microdefect data are mapped on the finite element model using grid data pass-algorithm, are obtained described limited
The microdefect data put on meta-model；
According to the microdefect data put on the finite element model, the springform of each unit in the finite element model is calculated
Amount；
The elasticity modulus of each unit is added in the finite element model, the finite element model comprising microdefect is obtained；
According to the microdefect data put on the finite element model, the SN curve comprising microdefect is established.
3. casting limited fatigue life member prediction technique according to claim 2, which is characterized in that described to use grid number
The microdefect data are mapped on the finite element model according to pass-algorithm, obtain put on the finite element model it is micro-
Defective data is seen, is specifically included:
The tetrahedron element comprising point P (x, y, z) on finite element model on casting process model is obtained, the tetrahedron element
First node, second node, third node and fourth node coordinate be respectively as follows: (x1, y1, z1), (x2, y2, z3), (x3, y3,
z3), (x4, y4, z4)；
Utilize formulaCalculate point P, second node, third node and the 4th on finite element model
The tetrahedral volume of node composition, obtains the first volume；
Utilize formulaCalculate point P, first node, third node and Section four on finite element model
The tetrahedral volume of point composition, obtains the second volume；
Utilize formulaCalculate point P, first node, second node and the 4th on finite element model
The tetrahedral volume of node composition, obtains third volume；
Utilize formulaCalculate point P, first node, second node and third section on finite element model
The tetrahedral volume of point composition, obtain fourth volume；
According to first volume, second volume, the third volume and the fourth volume, formula is utilizedCalculate the natural coordinates component (L of the tetrahedron element1, L2, L3, L4)；
Difference value equation λ is utilized according to the natural coordinates componentP=L1λ1+L2λ2+L3λ3+L4λ4, calculate point P on finite element model
The secondary dendrite length lambda of (x, y, z)P, wherein λ1、λ2、λ3And λ4The respectively first node of tetrahedron element, second node,
The secondary dendrite length of three nodes and fourth node；
Difference value equation Φ is utilized according to the natural coordinates componentP=L1Φ1+L2Φ2+L3Φ3+L4Φ4, calculate finite element model
The contraction cavity ratio Φ of upper P (x, y, z)P, wherein Φ1、Φ2、Φ3And Φ4The respectively first node of tetrahedron element, the second section
The contraction cavity ratio of point, third node and fourth node；
Utilize formula Φi=(Φi1+Φi2+Φi3+Φi4)/4 calculate i-th of unit in the finite element model comprising point P
The average value of each node contraction cavity ratio obtains the contraction cavity ratio Φ of i-th of uniti；Φi1, Φi2, Φi3And Φi4The four of i-th of unit
The contraction cavity ratio of a node；
According to the contraction cavity ratio Φ of i-th of uniti, utilize formulaCalculate i-th of list on finite element model
The shrinkage cavity area area of memberi, wherein ViFor the unit volume of i-th of unit of finite element model.
4. casting limited fatigue life member prediction technique according to claim 3, which is characterized in that according to the finite element
The microdefect data put on model, calculate the elasticity modulus of each unit in the finite element model, specifically include:
According to the contraction cavity ratio Φ of i-th of uniti, utilize formula Ei=E0(1-Φi), calculate the elasticity modulus of i-th of unit；Its
In, E0For the elasticity modulus of zero defect ideal material.
5. casting limited fatigue life member prediction technique according to claim 3, which is characterized in that described to have according to
The microdefect data put on limit meta-model, establish the SN curve comprising microdefect, specifically include:
According to the microdefect data put on the finite element model, formula is utilized
Calculate fatigue strength σ caused by microdefectD, wherein A, B, C and D are respectively the first relevant parameter, the second relevant parameter,
Three relevant parameters and the 4th relevant parameter；
The fatigue strength σ according to caused by microdefectD, establish the mathematical model of the relationship of mean stress and fatigue limit: Sa=
(1-R)Sm/ (1+R), wherein R is stress ratio,SmFor mean stress, SaFor mean stress Sm
Under fatigue limit, SuFor the breaking strength of material；
According to the mathematical model of mean stress and the relationship of fatigue limit, the SN curve comprising microdefect of each node is determined,
SnN=C, whereinC=Su n。
6. a kind of casting limited fatigue life member forecasting system, which is characterized in that the forecasting system includes:
Casting process model building module, for establishing the casting process model of casting；
Microdefect data acquisition module, for applying mold filling pressure, mold filling temperature, mold temperature to the casting process model
And heat transfer coefficient, casting process is simulated, microdefect data are obtained；The microdefect data include shrinkage cavity data and Secondary Branch
Brilliant data；
Finite element model establishes module, for establishing finite element model；
Mapping block, for the microdefect data to be mapped to the finite element model using grid data pass-algorithm
On, the finite element model comprising microdefect is established, and establish the SN curve comprising microdefect；
Finite element modelling module, for applying load to the finite element model comprising microdefect according to actual condition, into
Row finite element modelling obtains finite element modelling result；
Fatigue life prediction module is right for according to the finite element modelling result and the SN curve comprising microdefect
The fatigue life of casting is predicted.
7. casting limited fatigue life member forecasting system according to claim 5, which is characterized in that the mapping block,
It specifically includes:
Mapping submodule, for the microdefect data to be mapped to the finite element model using grid data pass-algorithm
On, obtain the microdefect data put on the finite element model；
Elasticity modulus computational submodule, for calculating described limited according to the microdefect data put on the finite element model
The elasticity modulus of each unit in meta-model；
Finite element model setting up submodule comprising microdefect, it is described limited for the elasticity modulus of each unit to be added to
In meta-model, the finite element model comprising microdefect is obtained；
SN curve setting up submodule comprising microdefect, for according to the microdefect data put on the finite element model,
Establish the SN curve comprising microdefect.
8. casting limited fatigue life member forecasting system according to claim 7, which is characterized in that the mapping submodule
Block specifically includes:
Tetrahedron element acquiring unit, for obtaining the four sides comprising point P (x, y, z) on finite element model on casting process model
Body unit, the first node of the tetrahedron element, second node, third node and fourth node coordinate be respectively as follows: (x1,
y1, z1), (x2, y2, z3), (x3, y3, z3), (x4, y4, z4)；
First volume computing unit, for utilizing formulaCalculate point P, the on finite element model
The tetrahedral volume of two nodes, third node and fourth node composition, obtains the first volume；
Second volume computing unit, for utilizing formulaCalculate point P, first on finite element model
The tetrahedral volume of node, third node and fourth node composition, obtains the second volume；
Third volume computing unit, for utilizing formulaCalculate point P, the on finite element model
The tetrahedral volume of one node, second node and fourth node composition, obtains third volume；
Fourth volume computing unit, for utilizing formulaCalculate point P, first on finite element model
The tetrahedral volume of node, second node and third node composition, obtain fourth volume；
Natural coordinates component calculation unit, for according to first volume, second volume, the third volume and described
Fourth volume utilizes formulaCalculate the natural coordinates component (L of the tetrahedron element1, L2, L3, L4)；
Difference value equation λ is utilized according to the natural coordinates componentP=L1λ1+L2λ2+L3λ3+L4λ4, calculate point P on finite element model
The secondary dendrite length lambda of (x, y, z)P, wherein λ1、λ2、λ3And λ4The respectively first node of tetrahedron element, second node,
The secondary dendrite length of three nodes and fourth node；
Difference value equation Φ is utilized according to the natural coordinates componentP=L1Φ1+L2Φ2+L3Φ3+L4Φ4, calculate finite element model
The contraction cavity ratio Φ of upper P (x, y, z)P, wherein Φ1、Φ2、Φ3And Φ4The respectively first node of tetrahedron element, the second section
The contraction cavity ratio of point, third node and fourth node；
Utilize formula Φi=(Φi1+Φi2+Φi3+Φi4)/4 calculate i-th of unit in the finite element model comprising point P
The average value of each node contraction cavity ratio obtains the contraction cavity ratio Φ of i-th of uniti；Φi1, Φi2, Φi3And Φi4The four of i-th of unit
The contraction cavity ratio of a node；
According to the average value Φ of each node contraction cavity ratio of i-th of uniti, utilize formulaCalculate finite element mould
The shrinkage cavity area area of i-th of unit in typei, wherein ViFor the unit volume of i-th of unit of finite element model.
9. casting limited fatigue life member forecasting system according to claim 7, which is characterized in that the springform meter
Operator module specifically includes:
Elasticity modulus computing unit, for the contraction cavity ratio Φ according to i-th of uniti, utilize formula Ei=E0(1-Φi), calculate i-th
The elasticity modulus of a unit；Wherein, E0For the elasticity modulus of zero defect ideal material.
10. casting limited fatigue life member forecasting system according to claim 8, which is characterized in that described comprising microcosmic
The SN curve setting up submodule of defect, specifically includes:
Calculation of Fatigue Strength unit caused by microdefect, for according to the microdefect data put on the finite element model,
Utilize formulaIt calculates tired caused by microdefect
Labor intensity σD, wherein A, B, C are respectively that the first relevant parameter, the second relevant parameter, third relevant parameter and the 4th are related to D
Parameter；
The mathematical model of the relationship of mean stress and fatigue limit establishes unit, is used for the fatigue strength according to caused by microdefect
σD, establish the mathematical model of the relationship of mean stress and fatigue limit: Sa=(1-R) Sm/ (1+R), wherein R is stress ratio,SmFor mean stress, SaFor mean stress SmUnder fatigue limit, SuIt is strong for the fracture of material
Degree；
SN curve determining unit determines the packet of each node for the mathematical model according to mean stress and the relationship of fatigue limit
SN curve containing microdefect, SnN=C, whereinC=Su n。
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