CN110807276A - Method and system for analyzing structural strength of casting by introducing residual stress - Google Patents
Method and system for analyzing structural strength of casting by introducing residual stress Download PDFInfo
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Abstract
The application relates to a method and a system for analyzing the structural strength of a casting by introducing residual stress, wherein the method comprises the following steps: introducing a casting digital model; performing modular flow analysis on the digital model to obtain a modular flow analysis model, and obtaining residual stress values and unit characteristics of each unit of the modular flow analysis model; corresponding the space coordinates of each unit of the modular flow analysis model to the digital model, and finding a unit set closest to each unit of the modular flow analysis model in the digital model space positions according to the space coordinates to obtain a structural analysis model; introducing the residual stress into each unit of the structural analysis model to serve as initial stress of each unit of the structural analysis model, and introducing the unit characteristics into each unit of the structural analysis model to obtain a corrected analysis model; and carrying out structural strength analysis aiming at the corrected analysis model. The method can reflect the actual manufacturability and unit characteristics of the aluminum alloy low-pressure casting, improve the accuracy of structural strength analysis and further improve the space for weight optimization.
Description
Technical Field
The application relates to the technical field of low-pressure metal casting processes, in particular to a method and a system for analyzing the structural strength of a casting by introducing residual stress.
Background
Weight reduction is an important issue facing the automotive industry in recent years and in the future. Due to the superior characteristics of aluminum alloys, the use of aluminum alloys has become a trend in automotive parts, with advantages including light weight, high strength, and the like.
The casting process is a common development and mass production mode of aluminum alloy parts. When the product design is carried out on an aluminum alloy casting product, structural analysis such as rigidity, strength, fatigue and the like needs to be carried out on structural characteristics. In the traditional analysis method, the characteristics of the unit to be analyzed are homogeneous, so that the problems of material deviation and the like in actual casting cannot be reflected, and the residual stress exists in the casting during the filling and solidification process of the actual casting. When the casting is cooled, plastic deformation occurs due to uneven expansion and contraction of the casting caused by temperature gradient change, and the casting also generates residual stress. Neglecting residual stress easily results in poor analysis efficiency, inaccurate analysis result, and influences the efficiency of analysis work and the material characteristics of actual products.
Disclosure of Invention
The technical problem to be solved by the invention is as follows: the method and the system for analyzing the structural strength of the casting by introducing the residual stress are provided for solving the defect of poor analysis effect in the analysis of the aluminum alloy casting design structure in the prior art.
The technical scheme adopted by the invention for solving the technical problems is as follows:
the method for analyzing the structural strength of the casting by introducing the residual stress comprises the following steps:
introducing a casting digital model;
performing modular flow analysis on the digital model to obtain a modular flow analysis model and obtaining residual stress values of all units of the modular flow analysis model;
corresponding the space coordinates of each unit of the modular flow analysis model to the digital model, and finding a unit set closest to each unit of the modular flow analysis model in the digital model space positions according to the space coordinates to obtain a structural analysis model;
introducing the residual stress into each unit of the structural analysis model to serve as initial stress of each unit of the structural analysis model, and introducing the initial stress into each unit of the structural analysis model to obtain a corrected analysis model;
and carrying out structural strength analysis aiming at the corrected analysis model.
In one embodiment, the step of introducing the residual stress into each unit of the structural analysis model as an initial stress of each unit of the structural analysis model, and introducing the initial stress into each unit of the structural analysis model to obtain a modified analysis model specifically includes:
the initial stress serves as a unit characteristic of the structural analysis model.
In one embodiment, the step of introducing the residual stress into each unit of the structural analysis model as an initial stress of each unit of the structural analysis model, and introducing the initial stress into each unit of the structural analysis model to obtain a modified analysis model specifically includes:
the stress of each unit of the corrected analysis model is real stress, and the sum of the stress of each unit of the structural analysis model and the initial stress obtains the real stress.
In one embodiment, the step of performing structural strength analysis on the modified analysis model specifically includes:
the structural strength analysis includes structural rigidity, strength and fatigue analysis.
A system for introducing residual stress analysis for structural strength of a casting, comprising:
the input module is used for leading in a casting digital-analog;
the module flow analysis module is used for carrying out module flow analysis on the digital-to-analog to obtain a module flow analysis model and obtaining the residual stress value of each unit of the module flow analysis model;
the structure analysis module is used for corresponding the space coordinates of each unit of the modular flow analysis model to the digital model, and finding a unit set closest to each unit of the modular flow analysis model in the digital model space positions according to the space coordinates to obtain a structure analysis model;
introducing the residual stress into each unit of the structural analysis model to serve as initial stress of each unit of the structural analysis model, and introducing the initial stress into each unit of the structural analysis model to obtain a corrected analysis model;
and the stress analysis module is used for carrying out structural strength analysis on the corrected analysis model.
In one embodiment, the initial stress is used as a cell characteristic of the structural analysis model.
In one embodiment, the stress of each unit of the modified analysis model is a real stress, and the sum of the stress of each unit of the structural analysis model and the initial stress obtains the real stress.
In one embodiment, when the stress analysis module performs structural strength analysis on the modified analysis model, the structural strength analysis includes structural rigidity, strength and fatigue analysis.
The invention has the beneficial effects that: according to the invention, the residual stress value in the mold flow analysis result is used as a basis, and is introduced into the structural analysis model, so that the actual manufacturability and unit characteristics of the aluminum alloy low-pressure casting can be reflected, and in the structural analysis, if the residual stress generated in the casting process can be considered, a more real unit stress condition can be reflected, so that the accuracy of structural strength analysis is improved, and further, the weight optimization space is improved; through the mode of finding the proximity unit by coordinates, the mode flow analysis and the grid of the structural analysis do not need to be completely the same, only the integral object is required to keep the original coordinate system, the grid can be adjusted and subdivided in the model of the structural analysis, and the analysis efficiency and the working flexibility are greatly improved.
Drawings
The technical solution of the present application is further explained below with reference to the drawings and the embodiments.
FIG. 1 is a schematic flow chart of an embodiment of the present application directed to a method for analyzing structural strength of a casting;
FIG. 2 is a schematic structural diagram of an embodiment of the system for analyzing structural strength of castings by introducing residual stress according to the present application.
Detailed Description
It should be noted that the embodiments and features of the embodiments in the present application may be combined with each other without conflict.
In the description of the present application, it is to be understood that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," and the like are used in the orientation or positional relationship indicated in the drawings for convenience in describing the present application and for simplicity in description, and are not intended to indicate or imply that the referenced devices or elements must have a particular orientation, be constructed in a particular orientation, and be operated in a particular manner, and are not to be considered limiting of the scope of the present application. Furthermore, the terms "first", "second", etc. are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first," "second," etc. may explicitly or implicitly include one or more of that feature. In the description of the invention, the meaning of "a plurality" is two or more unless otherwise specified.
In the description of the present application, it is to be noted that, unless otherwise explicitly specified or limited, the terms "mounted," "connected," and "connected" are to be construed broadly, e.g., as meaning either a fixed connection, a removable connection, or an integral connection; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meaning of the above terms in the present application can be understood by those of ordinary skill in the art through specific situations.
The technical solutions of the present application will be described in detail below with reference to the accompanying drawings in conjunction with embodiments.
Referring to fig. 1, the method for analyzing the structural strength of a casting by introducing residual stress according to the present invention includes the following steps:
step S1, importing a casting digital model;
step S2, performing modular flow analysis on the digital model to obtain a modular flow analysis model, and obtaining residual stress values of all units of the modular flow analysis model;
step S3, the space coordinates of each unit of the modular flow analysis model are corresponding to the digital model, and the unit set closest to the position of each unit of the modular flow analysis model in the digital model space positions is found according to the space coordinates to obtain a structural analysis model;
step S4, introducing residual stress into each unit of the structural analysis model as initial stress of each unit of the structural analysis model, and introducing the initial stress into each unit of the structural analysis model to obtain a corrected analysis model;
step S5, structural strength analysis is performed on the corrected analysis model.
In step S1, the casting digital model may be a digital model of a low-pressure aluminum alloy casting, and since the generation of the casting digital model is already a mature technology, the present invention is not described in detail, and those skilled in the art can refer to the current modeling technology to complete the process. In step S2, the residual stress is self-balanced internal stress remaining in the object after eliminating the external force or the uneven temperature field, and both the machining and the strengthening process can cause the residual stress, such as cold drawing, bending, cutting, rolling, shot blasting, casting, forging, welding, and metal heat treatment, which may cause the residual stress due to uneven plastic deformation or phase change. Residual stresses are generally detrimental to the structure, as the part may be subjected to improper heat treatment, welding or machining, and may cause the part to warp or distort and even crack. The mold flow analysis means that the simulation of casting molding is completed through a computer by using data simulation software, the process of mold casting is simulated, some data results are obtained, and the feasibility of the scheme of the mold is evaluated through the results, so that the mold design scheme and the product design scheme are perfected. Common software for die FLOW pack coagulation analysis are Moldflow, Moldex3D, PROCAST, FLOW3D, and the like.
In step S3, the spatial coordinates of each unit of the model flow analysis model are associated with the digital model, and according to the method of the corresponding unit, the unit closest to the position of each unit of the model flow analysis model in the digital model spatial position is found and obtained according to the spatial coordinates, and the structural analysis model is obtained according to the unit set.
In step S5, structural strength analysis is performed on the corrected analysis model. The structural strength analysis is a common analysis method in the field for researching the load bearing capacity of a structure under a normal temperature condition, and is not described in detail.
In this embodiment, the model unit is mapped by finding the nearest unit by using a point finding method of spatial coordinates, and then introducing a correction coefficient to correct the unit characteristics of the structural analysis model unit. Through the way of finding the proximity unit by coordinates, the grids of the modular flow analysis and the structural analysis are not required to be completely the same, and only the integral object is required to keep the original coordinate system. The user can adjust the grids and subdivide the grids in the structural analysis model, so that the analysis efficiency and the working flexibility of the user are greatly improved.
In this embodiment, the residual stress in the mold flow analysis result is introduced into the structural analysis model, so that the manufacturability and unit characteristics of actual low-pressure casting can be reflected, the accuracy of structural analysis is improved, and the space for weight optimization is further improved.
The invention principle is that in the conventional structural analysis method, the initial stress in the conventional structural analysis unit is 0 because the residual stress generated by the solidification and cooling of the casting and the like is relatively small and is ignored in the structural analysis. By the analysis method, residual stress results generated in the casting, cooling and solidifying processes can be superposed, and the real stress of each unit can be more accurately predicted, namely the sum of the residual stress and the structural analysis stress result is the final predicted real stress.
In one embodiment, the PROCAST output residual stress value is imported, and the ABAQUS structural analysis model is imported as the initial stress.
In one embodiment, the step of introducing the residual stress into each unit of the structural analysis model as the initial stress of each unit of the structural analysis model, and introducing the unit characteristics into each unit of the structural analysis model to obtain the modified analysis model specifically includes: the cell characteristics include material tensile and yield.
In one embodiment, the step of introducing the residual stress into each unit of the structural analysis model as an initial stress of each unit of the structural analysis model, and introducing the initial stress into each unit of the structural analysis model to obtain the modified analysis model specifically includes: and correcting the stress of each unit of the analysis model into real stress, and obtaining the real stress by the sum of the stress of each unit of the structural analysis model and the initial stress.
In one embodiment, the step of performing structural strength analysis on the modified analysis model specifically includes: structural strength analysis includes structural rigidity, strength and fatigue analysis.
Referring to fig. 2, an embodiment of the present invention further provides a system for analyzing structural strength of a casting by introducing residual stress, which can implement all processes of the method provided by the foregoing embodiment, including:
the input module 10 is used for leading in a casting digital-analog;
the module flow analysis module 20 is used for performing module flow analysis on the digital-to-analog to obtain a module flow analysis model and obtaining residual stress values of all units of the module flow analysis model;
the structure analysis module 30 is configured to correspond the spatial coordinates of each unit of the modular flow analysis model to a digital model, and find a unit set closest to each unit of the modular flow analysis model in the digital model spatial positions according to the spatial coordinates to obtain a structure analysis model;
the correction module 40 is used for introducing the residual stress into each unit of the structural analysis model as the initial stress of each unit of the structural analysis model and introducing the initial stress into each unit of the structural analysis model to obtain a corrected analysis model;
and the stress analysis module 50 is used for carrying out structural strength analysis on the corrected analysis model.
In one embodiment, the initial stress is used as a cell property of the structural analysis model, and the cell property includes material tensile and yield. The yield strength, which is the yield limit of the metal material when yielding, i.e., the stress against micro plastic deformation, is an important unit property. The tensile strength represents the tensile strength of the metal material, the tensile strength is a critical value of the transition of the metal from uniform plastic deformation to local concentrated plastic deformation, and is also the maximum bearing capacity of the metal under a static stretching condition, and is an important unit characteristic.
In one embodiment, the stress of each unit of the modified analysis model is the real stress, and the sum of the stress of each unit of the structural analysis model and the initial stress obtains the real stress.
In one embodiment, the stress analysis module 50 performs structural strength analysis on the modified analysis model, the structural strength analysis including structural rigidity, strength, and fatigue analysis.
In one embodiment of the present invention, the solidification cooling, the SDAS value, the residual stress, etc. may be output through the Procast mold flow analysis, for example, the castability of a certain portion in the mold flow analysis is not good, and the residual stress value of one unit in the region is 30 Mpa. Then, by the method or system, the corresponding cell set or cell (more than one cell is called as a cell set) in the structural analysis is found by using the spatial coordinates, and then 30MPa is input to the corresponding structural analysis model cell as the initial stress. When the structure is analyzed in the prior art, the influence of residual stress caused by manufacturability can not be considered, and the stress analysis of the structure is directly carried out by neglecting the residual stress. Assuming that the region is analyzed to have a stress of 254MPa, we consider that the stress here is 254MPa, and in fact the actual stress may be larger, which causes an error between the actual situation and the simulation. In the embodiment, the residual stress is introduced into the unit in the region of the structural analysis as the initial stress, and the structural analysis result is superposed after being calculated, so that the stress is 284MPa, which is more close to the actual situation.
The invention has the beneficial effects that: according to the invention, the residual stress value in the mold flow analysis result is used as a basis, and is introduced into the structural analysis model, so that the actual manufacturability and unit characteristics of the aluminum alloy low-pressure casting can be reflected, and in the structural analysis, if the residual stress generated in the casting process can be considered, a more real unit stress condition can be reflected, so that the accuracy of structural strength analysis is improved, and further, the weight optimization space is improved; through the mode of finding the proximity unit by coordinates, the mode flow analysis and the grid of the structural analysis do not need to be completely the same, only the integral object is required to keep the original coordinate system, the grid can be adjusted and subdivided in the model of the structural analysis, and the analysis efficiency and the working flexibility are greatly improved.
In light of the foregoing description of the preferred embodiments according to the present application, it is to be understood that various changes and modifications may be made without departing from the spirit and scope of the invention. The technical scope of the present application is not limited to the contents of the specification, and must be determined according to the scope of the claims.
Claims (8)
1. The method for analyzing the structural strength of the casting by introducing the residual stress is characterized by comprising the following steps of:
introducing a casting digital model;
performing modular flow analysis on the digital model to obtain a modular flow analysis model and obtaining residual stress values of all units of the modular flow analysis model;
corresponding the space coordinates of each unit of the modular flow analysis model to the digital model, and finding a unit set closest to each unit of the modular flow analysis model in the digital model space positions according to the space coordinates to obtain a structural analysis model;
introducing the residual stress into each unit of the structural analysis model to serve as initial stress of each unit of the structural analysis model, and introducing the initial stress into each unit of the structural analysis model to obtain a corrected analysis model;
and carrying out structural strength analysis aiming at the corrected analysis model.
2. The method for analyzing the structural strength of a casting by introducing residual stress according to claim 1, wherein the step of introducing the residual stress into each unit of the structural analysis model as an initial stress of each unit of the structural analysis model and introducing the initial stress into each unit of the structural analysis model to obtain a corrected analysis model specifically comprises:
the initial stress serves as a unit characteristic of the structural analysis model.
3. The method for analyzing the structural strength of a casting by introducing residual stress according to claim 1, wherein the step of introducing the residual stress into each unit of the structural analysis model as an initial stress of each unit of the structural analysis model and introducing the initial stress into each unit of the structural analysis model to obtain a corrected analysis model specifically comprises:
the stress of each unit of the corrected analysis model is real stress, and the sum of the stress of each unit of the structural analysis model and the initial stress obtains the real stress.
4. The method for analyzing the structural strength of the casting by introducing the residual stress according to claim 1, wherein the step of analyzing the structural strength of the casting by aiming at the corrected analysis model specifically comprises the following steps:
the structural strength analysis includes structural rigidity, strength and fatigue analysis.
5. A system for analyzing the structural strength of a casting by introducing residual stress, comprising:
the input module is used for leading in a casting digital-analog;
the module flow analysis module is used for carrying out module flow analysis on the digital-to-analog to obtain a module flow analysis model and obtaining the residual stress value of each unit of the module flow analysis model;
the structure analysis module is used for corresponding the space coordinates of each unit of the modular flow analysis model to the digital model, and finding a unit set closest to each unit of the modular flow analysis model in the digital model space positions according to the space coordinates to obtain a structure analysis model;
introducing the residual stress into each unit of the structural analysis model to serve as initial stress of each unit of the structural analysis model, and introducing the initial stress into each unit of the structural analysis model to obtain a corrected analysis model;
and the stress analysis module is used for carrying out structural strength analysis on the corrected analysis model.
6. The system for introducing residual stress analysis casting structural strength of claim 5, wherein the initial stress is a unit property of the structural analysis model.
7. The system for introducing residual stress analysis casting structural strength according to claim 5, wherein the stress of each element of the modified analysis model is a true stress, and the sum of the stress of each element of the modified analysis model and the initial stress obtains the true stress.
8. The system for importing structural strength of residual stress analysis castings according to claim 5, wherein the structural strength analysis includes structural rigidity, strength and fatigue analysis when the stress analysis module performs structural strength analysis on the modified analysis model.
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