CN113102735B - Immersion type three-dimensional ultrasonic metal solidification device and method with controllable sound field - Google Patents
Immersion type three-dimensional ultrasonic metal solidification device and method with controllable sound field Download PDFInfo
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- CN113102735B CN113102735B CN202110339793.XA CN202110339793A CN113102735B CN 113102735 B CN113102735 B CN 113102735B CN 202110339793 A CN202110339793 A CN 202110339793A CN 113102735 B CN113102735 B CN 113102735B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
- B22D27/20—Measures not previously mentioned for influencing the grain structure or texture; Selection of compositions therefor
Abstract
The invention discloses an immersion type three-dimensional ultrasonic metal solidification device and method with a controllable sound field, wherein the device comprises a metal solidification device body and a metal solidification data acquisition and controller, wherein the metal solidification device body comprises a casting mold and an ultrasonic vibration component; the metal solidification data acquisition and control device comprises an acoustic signal acquisition circuit, a computer, a multi-path signal generator, a multi-path signal amplifier and a sound pressure sensor group; the method comprises the following steps: firstly, loading alloy raw materials; secondly, installing a metal solidification device body; thirdly, mounting a sound pressure sensor; fourthly, setting an initial value of a vibration parameter; fifthly, smelting the master alloy; sixthly, melt casting; seventhly, performing wall surface vibration three-dimensional ultrasonic metal solidification under the feedback control of vibration frequency, phase and amplitude; and eighthly, unloading the casting. The invention can automatically track the input target sound field through the acoustic signal feedback in the melt, realize the controllable ultrasonic treatment of the large-volume melt, realize the improvement of the casting performance and facilitate the popularization and the use of the casting industry.
Description
Technical Field
The invention belongs to the field of advanced material preparation and processing, and particularly relates to an immersion type three-dimensional ultrasonic metal solidification device and method with a controllable sound field.
Background
Casting is one of important metal forming techniques, and has a wide range of applications, such as aerospace vehicle engine parts, airfoil support members, automobile engine cylinders and gearbox housings, automobile hubs, and complex parts for many mechanical devices. The specific material relates to aluminum alloy, magnesium alloy, copper alloy, nickel-based high-temperature alloy and the like. The continuous improvement and the improvement of the performance of the casting have important significance for the development of various industries.
The casting process is a process in which the metal melt is gradually solidified in the cavity. Research shows that when an ultrasonic field is applied in the process of metal solidification, a series of nonlinear effects such as cavitation and acoustic flow generated by ultrasonic waves in a liquid phase can be utilized to obviously influence nucleation, heat and solute transmission of a metal melt, so that pores can be eliminated, segregation can be inhibited, grains can be refined, and mechanical properties can be improved. However, the current ultrasonic casting does not really enter the industrial casting field, and the main reason of the current ultrasonic casting is that the following defects exist in the prior art:
(1) in the prior art, a horn at an ultrasonic transmitting end is immersed in a melt to transmit ultrasonic waves, and the temperature of the horn is increased due to heat transfer of the melt, so that the propagation speed and the wavelength of the inside of the horn are changed, and the horn deviates from a resonance point of standing waves to stop working. Even when the temperature rises to a higher level, the structure of the amplitude transformer is changed, and the amplitude transformer is subjected to plastic deformation or cracks, so that the amplitude transformer is permanently failed, and therefore, the ultrasonic welding method cannot be applied to ultrasonic solidification of high-temperature metal.
(2) In the prior art, one-dimensional ultrasonic waves with fixed frequency and amplitude are directly applied to a metal melt, vibration energy is quickly attenuated, the action range is small, and the length distance of generally effective refined grains is only 4-5 cm.
(3) In the prior art, one-dimensional ultrasonic vibration with the top extending into an ultrasonic amplitude transformer is mostly adopted, one-dimensional ultrasonic can only realize a one-dimensional gradient field along the ultrasonic emission direction, but cannot realize a uniform intensity field and other distribution field forms, the distribution form of an ultrasonic field cannot be regulated and controlled, and the liquid-solid phase change process cannot be finely controlled; if the metal melt is stretched into the melt in multiple directions to vibrate, the metal melt is easy to leak, or the amplitude transformer is restrained by the wall of the casting mould and cannot work.
(4) The prior art can only adjust the ultrasonic wave transmitting power generally, but lacks the measurement of the actual existing sound pressure and the distribution thereof in the melt, and can not accurately give effective technological parameters, thereby being incapable of realizing the effective regulation and control of the solidification structure.
In conclusion, the conventional ultrasonic solidification technology cannot cool and protect the amplitude transformer of ultrasonic vibration emission, has limited ultrasonic treatment volume and lacks of actual sound pressure measurement in a melt, and cannot accurately regulate and control the sound field form. These are bottlenecks that limit the true migration of ultrasound into industrial applications.
Disclosure of Invention
The invention aims to solve the technical problem of providing the immersion type three-dimensional ultrasonic metal solidification device with a controllable sound field, which has novel and reasonable design, expands the range of cavitation and acoustic flow effects by extending ultrasonic amplitude transformers in multiple directions into the outer wall of a casting mould, overcomes the defect of small one-dimensional ultrasonic action range and can realize the homogenization of the microstructure of a large-size metal sample.
In order to solve the technical problems, the invention adopts the technical scheme that: the utility model provides a three-dimensional supersound metal solidification equipment of immersion of controllable sound field which characterized in that: the metal solidification device comprises a metal solidification device body and a metal solidification data acquisition and controller, wherein the metal solidification device body comprises a casting mold poured from the top and ultrasonic vibration components arranged on the outer wall of the casting mold in multiple directions, each ultrasonic vibration component comprises an ultrasonic transducer, an amplitude transformer connected to the front end of the ultrasonic transducer and a displacement controller connected to the ultrasonic transducer and used for driving the ultrasonic transducer to move, the amplitude transformer extends into the outer wall of the casting mold, a cooler hermetically connected with the casting mold and the amplitude transformer is sleeved on the amplitude transformer, and a master alloy pool used for heating and melting solid alloy raw materials and casting the solid alloy raw materials into the casting mold is arranged above the casting mold;
the metal solidification data acquisition and controller comprises an acoustic signal acquisition circuit, a computer, a multi-channel signal generator, a multi-channel signal amplifier and a sound pressure sensor group arranged in the casting mold, wherein the acoustic signal acquisition circuit, the computer, the multi-channel signal generator and the multi-channel signal amplifier are sequentially connected, the sound pressure sensor group comprises a plurality of first sound pressure sensors which are arranged near the transmitting end of an amplitude transformer in the casting mold and used for measuring vibration sound pressure and a plurality of second sound pressure sensors which are arranged in the casting mold and used for measuring sound pressure distribution in a melt, and the first sound pressure sensors and the second sound pressure sensors are both connected with the acoustic signal acquisition circuit; the ultrasonic transducer is connected with the output end of the multi-path signal amplifier, and the multi-path signal amplifier is connected with the computer.
The immersion type three-dimensional ultrasonic metal solidification device with the controllable sound field is characterized in that: the casting mould is in a shape of a right quadrangular prism, and the ultrasonic vibration assemblies are arranged in three orthogonal directions of the outer wall of the casting mould.
The immersion type three-dimensional ultrasonic metal solidification device with the controllable sound field is characterized in that: the displacement controller comprises a lead screw base, a lead screw connected to the lead screw base, a lead screw nut in threaded connection with the lead screw and a motor for driving the lead screw to rotate, and the ultrasonic transducer is connected to the lead screw nut.
The immersion type three-dimensional ultrasonic metal solidification device with the controllable sound field is characterized in that: the cooler comprises a cooling jacket which is sleeved on the amplitude transformer and internally provided with a cooling water channel, a gap is reserved between the inner wall of the cooling jacket and the outer wall of the amplitude transformer, a metal heat-conducting agent is filled in the gap, a flange is arranged on one side of the cooling jacket close to the casting mold and is connected with the outer wall surface of the casting mold through the flange, a heat-resistant sealing gasket used for sealing the gap among the amplitude transformer, the casting mold and the cooling jacket is arranged on one side of the cooling jacket, which is in contact with the casting mold, an outer sealing gasket used for sealing the metal heat-conducting agent is arranged on the other side of the cooling jacket, and an end cover used for compressing the outer sealing gasket is fixedly connected to the cooling jacket.
The immersion type three-dimensional ultrasonic metal solidification device with the controllable sound field is characterized in that: the bottom outflow hole of the master alloy pool is connected with a casting pipeline communicated into the casting mold, and a plug rod capable of plugging the outflow hole is placed in the master alloy pool.
The immersion type three-dimensional ultrasonic metal solidification device with the controllable sound field is characterized in that: the end surface of the amplitude transformer extending into the outer wall of the casting mould is flush with the inner wall surface of the casting mould.
The immersion type three-dimensional ultrasonic metal solidification device with the controllable sound field is characterized in that: the value of the length L of the amplitude transformer meets the formula under the condition of being as small as possible
And satisfy the formula L1·η1+L2·η2>kL·(TL-Tc) (ii) a Wherein L is1Length of the portion of the horn housing the cooler, L2The length of the amplitude transformer exposed outside the cooler is shown, m is a multiple coefficient, the value of m is a non-0 natural number, lambda is the ultrasonic wavelength in the amplitude transformer, and k isLFor the length of the horn, TLThe maximum temperature of the melt in the casting mould, TcIs the failure temperature, eta, of the vibrating crystal inside the ultrasonic transducer1Temperature drop coefficient, eta, of the section of the horn housing the cooler2The temperature drop coefficient of the amplitude transformer exposed outside the cooler is shown.
The immersion type three-dimensional ultrasonic metal solidification device with the controllable sound field is characterized in that: the number of the first sound pressure sensors is equal to that of the amplitude transformer, the cross sectional area of a detecting head of each first sound pressure sensor is less than 10% of that of the end of each amplitude transformer, and the bottom surface of the detecting head of each first sound pressure sensor is flush with the top surface extension surface of the amplitude transformer; the number of the second sound pressure sensors is 5-15.
The invention also discloses an immersion type three-dimensional ultrasonic metal solidification method of a controllable sound field, which is characterized by comprising the following steps of:
step one, alloy raw material loading: filling a multi-component alloy solid raw material into a master alloy pool;
step two, installing a metal solidification device body: the displacement controller drives the whole of the ultrasonic transducer, the amplitude transformer and the cooler to move towards the direction of the casting mould, so that the amplitude transformer extends into the outer wall of the casting mould, and the end surface of the amplitude transformer extending into the outer wall of the casting mould is flush with the inner wall surface of the casting mould;
step three, installing a sound pressure sensor: a first sound pressure sensor is arranged near the transmitting end of each amplitude transformer, a plurality of second sound pressure sensors are uniformly distributed in the casting mold, the first sound pressure sensors and the second sound pressure sensors are connected with a sound signal acquisition circuit, and the target sound pressure values of the second sound pressure sensors are input into a computer;
step four, setting an initial value of a vibration parameter: setting vibration parameter initial values of the ultrasonic transducers, wherein the vibration parameter initial values comprise the amplitudes and the vibration frequencies of the ultrasonic transducers and phase differences among the ultrasonic transducers;
step five, smelting the master alloy: heating and melting the alloy solid raw materials in the master alloy pool, and preserving heat;
step six, melt pouring: pouring the melt in the master alloy pool into a casting mold;
seventhly, performing wall surface vibration three-dimensional ultrasonic metal solidification under the feedback control of vibration frequency, phase and amplitude, wherein the concrete process is as follows:
701, the computer sends a vibration frequency instruction and a phase difference instruction to a multi-path signal generator and sends an amplitude instruction to a multi-path signal amplifier according to an initial value of a vibration parameter; the electric signals sent by the multi-path signal generator are transmitted to a multi-path signal amplifier, the signals amplified by the multi-path signal amplifier are output to the ultrasonic transducer to drive the ultrasonic transducer, and the ultrasonic transducer starts to vibrate according to the initial value of the vibration parameters; in the vibration process of the ultrasonic transducer, a first sound pressure sensor collects sound pressure signals of each amplitude transformer, a second sound pressure sensor collects sound pressure signals in a melt, the collected sound pressure signals are transmitted to a sound signal collecting circuit through a cable and then transmitted to a computer, and the computer compares the sound pressure signals collected by the second sound pressure sensor with a target sound pressure value to obtain a deviation evaluation value;
step 702, the computer takes the vibration frequency of each ultrasonic transducer as a regulation parameter at f0-△f～f0Changing a vibration frequency parameter within the value range of +/-af, vibrating the ultrasonic transducer according to the vibration parameter after the vibration frequency is changed, and changing the sound pressure value detected by the first sound pressure sensor; determining the vibration frequency parameter corresponding to the maximum sound pressure value in the whole value range of the vibration frequency parameter as the optimal vibration frequency parameter by the computer; wherein f is0Is the initial value of the vibration frequency, and delta f is the variation value of the vibration frequency;
703, controlling the ultrasonic transducers to vibrate by the computer according to the optimal vibration frequency parameter, changing the phase difference parameter by taking the phase difference among the plurality of ultrasonic transducers as a regulation parameter according to a set step length within a value range of 0-2 pi, vibrating the ultrasonic transducers according to the vibration parameter after changing the phase difference, and changing the deviation evaluation value; the computer determines the phase difference parameter corresponding to the minimum deviation evaluation value in the whole value range of the phase difference parameter as the optimal phase difference parameter;
step 704, the computer controls the ultrasonic transducers to vibrate according to the optimal vibration frequency and the optimal phase difference parameter, and the amplitudes of the ultrasonic transducers are used as regulation parameters and are controlled to be within 0-AmaxChanging amplitude parameters according to the set step length, vibrating the ultrasonic transducer according to the vibration parameters after changing the amplitude, and changing the deviation evaluation value; the computer determines the amplitude parameter corresponding to the minimum deviation evaluation value in the whole value range of the amplitude parameter as the optimal amplitude parameter; wherein A ismaxThe maximum amplitude that can be achieved by the ultrasonic transducer;
705, the computer displays the prompt of finding the optimal vibration frequency parameter, the optimal phase difference parameter and the optimal amplitude parameter;
step 706, the computer controls the ultrasonic transducer to vibrate according to the optimal vibration frequency parameter, the optimal phase difference parameter and the optimal amplitude parameter until the alloy melt is completely solidified;
step 707, turning off the ultrasonic transducer;
in the working process, the computer displays the deviation evaluation value, the vibration frequency parameter, the phase difference parameter and the amplitude parameter in real time;
step eight, unloading the casting: and after the solid sample is cooled to room temperature, unloading the ultrasonic vibration assembly, unloading the casting mold and taking out the casting.
The above method is characterized in that: the casting mould is in a shape of a straight quadrangular prism, the number of the ultrasonic vibration assemblies is three, the three ultrasonic vibration assemblies are respectively an X-axis ultrasonic vibration assembly, a Y-axis ultrasonic vibration assembly and a Z-axis ultrasonic vibration assembly, and the X-axis ultrasonic vibration assembly, the Y-axis ultrasonic vibration assembly and the Z-axis ultrasonic vibration assembly are arranged in three orthogonal directions of the outer wall of the casting mould;
inputting the coordinate data of each second sound pressure sensor into the computer in the third step; the computer records the target sound pressure value of the ith second sound pressure sensor as x in an array formi,yi,zi,S′i](ii) a In the seventh step, the computer records the sound pressure value detected by the ith second sound pressure sensor as x in an array formi,yi,zi,Si](ii) a Wherein x isiIs the X-axis coordinate value, y, of the ith second acoustic pressure sensoriIs the Y-axis coordinate value, z, of the ith second acoustic pressure sensoriFor the ith second sound pressureThe value of Z-axis coordinate value of the sensor, i is a natural number from 1 to n, n is the total number of the second acoustic pressure sensors, S'iIs a target sound pressure value, S, of the ith second sound pressure sensoriThe sound pressure value detected by the ith second sound pressure sensor;
the phase difference in the fourth step comprises the phase difference phi of the X-axis ultrasonic vibration component and the Y-axis ultrasonic vibration component1And the phase difference phi between the X-axis ultrasonic vibration component and the Z-axis ultrasonic vibration component2(ii) a Phase difference phi1And a phase difference phi2All initial values of (1) are 0; in step four, the amplitude includes the amplitude A of the X-axis ultrasonic vibration componentXAmplitude a of the Y-axis ultrasonic vibration assemblyYAnd amplitude A of Z-axis ultrasonic vibration assemblyZ(ii) a Amplitude AXHas an initial value of AX maxAmplitude AYHas an initial value of AY maxAmplitude AZHas an initial value of AZ max；AX maxMaximum amplitude, A, of the X-axis ultrasonic vibration assemblyY maxMaximum amplitude, A, of the Y-axis ultrasonic vibration assemblyZ maxThe maximum amplitude that can be achieved by the Z-axis ultrasonic vibration component; in step four, the vibration frequency comprises the vibration frequency f of the X-axis ultrasonic vibration componentXVibration frequency f of Y-axis ultrasonic vibration componentYAnd the vibration frequency f of the Z-axis ultrasonic vibration componentZ；
The phase difference in steps 701 and 703 includes a phase difference phi between the X-axis ultrasonic vibration component and the Y-axis ultrasonic vibration component1And the phase difference phi between the X-axis ultrasonic vibration component and the Z-axis ultrasonic vibration component2；
The amplitudes in steps 701 and 704 include the amplitude A of the X-axis ultrasonic vibration componentXAmplitude a of the Y-axis ultrasonic vibration assemblyYAnd amplitude A of Z-axis ultrasonic vibration assemblyZ(ii) a The step size in step 704 includes an amplitude AXStep size of variation 0.1AX maxAmplitude AYStep size of variation 0.1AY maxAmplitude AZStep size of variation 0.1AZ maxAmplitude AXIn the range of 0 to AX maxWithin a value range of (A), amplitude AYIn the range of 0 to AY maxValue ofWithin a range of amplitude AZIn the range of 0 to AZ maxAccording to a set step length and according to an amplitude AXAmplitude AYAnd amplitude AZForm comprehensive values of the three-dimensional array are formed;
the calculation formula of the deviation evaluation value sigma in steps 701, 703 and 704 is
Wherein, S'iIs a target sound pressure value, S, of the ith second sound pressure sensoriThe sound pressure value detected by the ith second sound pressure sensor;
in step 705, after the computer displays the prompt that the optimal vibration frequency parameter, the optimal phase difference parameter, and the optimal amplitude parameter have been found, the staff removes the plurality of second sound pressure sensors.
Compared with the prior art, the invention has the following advantages:
1. according to the invention, the amplitude transformer is sleeved with the cooler, and the metal heat-conducting agent is filled between the inner wall of the cooling sleeve and the outer wall of the amplitude transformer, so that a cooling mode combining contact type liquid metal cooling and water cooling is realized, the temperature of the amplitude transformer is stabilized in a low-temperature region, and the ultrasonic treatment of high-temperature metal can be carried out; the service life of the amplitude transformer is effectively prolonged, the problems that the amplitude transformer is overheated to cause system failure, the ultrasonic output is interrupted, and even the amplitude transformer is plastically deformed or cracked to cause permanent failure of the amplitude transformer and failure of ultrasonic treatment in the solidification process are avoided, and the microstructure and the performance of a casting cannot be effectively improved.
2. The invention enlarges the range of cavitation and acoustic flow effect by arranging the ultrasonic vibration components in multiple directions on the outer wall of the casting mould and mutually superposing multiple ultrasonic waves to act in the melt, solves the defect of small one-dimensional ultrasonic action range, can realize the homogenization of the microstructure of a large-size metal sample, and has outstanding progress compared with the prior art.
3. By designing the structures of the ultrasonic vibration component and the cooler, the amplitude transformer extends into the outer wall of the casting mould, the cooler is hermetically connected with the casting mould and the amplitude transformer, the amplitude transformer is not directly contacted with the main body part of the cooler and the casting mould, and is contacted with the heat-resistant sealing gasket and the outer sealing gasket, so that the leakage of metal melt is avoided, the vibration of the amplitude transformer is not restricted by the wall of the casting mould and the cooler, and the problem of vibration implementation of the ultrasonic amplitude transformer extending into the melt in multiple directions is solved; by adopting ultrasonic vibration in multiple directions, phase difference and amplitude parameters of multi-dimensional ultrasonic can be independently regulated and controlled, so that a vibration sound field after wave superposition can be regulated and controlled, regulation of ultrasonic field distribution forms such as uniform intensity field and gradient field is realized, and the defect that morphological characteristics of a one-dimensional ultrasonic field are not regulated and controlled is effectively overcome.
4. On the basis of setting multi-direction ultrasonic vibration, a plurality of first sound pressure sensors for measuring vibration sound pressure near the transmitting end of an amplitude transformer in a casting mould and a plurality of second sound pressure sensors which are arranged in the casting mould and used for measuring sound pressure distribution in a melt are also arranged, so that not only can a sound pressure signal of each amplitude transformer be detected, but also the sound pressure distribution in the melt can be detected, and then the sound pressure signals are combined in an immersed three-dimensional ultrasonic metal solidification method of a controllable sound field to perform feedback control on vibration frequency, phase difference parameters and amplitude, and finally, the tracking of an actual sound field and a target sound field is realized, and the automatic regulation and control of an ultrasonic field in the melt are realized; the method solves the problem that the prior art is lack of sound pressure measurement in the melt and cannot accurately set effective process parameters.
5. According to the immersion type three-dimensional ultrasonic metal solidification method of the controllable sound field, the deviation evaluation value of the sound pressure distribution in the melt and the target sound pressure value is used as a regulation and control standard, the phase difference parameter and the amplitude parameter are regulated and controlled, the optimal phase difference parameter and the optimal amplitude parameter can be effectively obtained, the optimal frequency scanning is further combined, and the efficient emission of ultrasonic waves can be realized.
6. The invention adopts the superposition effect of power ultrasonic generated waves which are independently controlled in multiple paths and are provided with a metal liquid cooling device (cooler), realizes the effective application of an ultrasonic field in a metal melt in a larger range, detects the sound field in the melt through a sound pressure sensor, compares the sound field with an input expected target sound field, automatically regulates and controls the vibration frequency, the phase and the amplitude parameter of three-dimensional ultrasonic in real time, realizes the automatic tracking of the target sound field, realizes the accurate controllability of an ultrasonic solidification technology, greatly improves the microstructure of a casting and improves the mechanical property of the casting.
In conclusion, the ultrasonic-ultrasonic.
The technical solution of the present invention is further described in detail by the accompanying drawings and embodiments.
Drawings
FIG. 1 is a schematic structural diagram of an immersion type three-dimensional ultrasonic metal solidification device with controllable sound field according to the present invention;
FIG. 2 is a schematic view showing the connection of the ultrasonic vibration unit, the displacement controller and the cooler according to the present invention;
FIG. 3 is a schematic diagram of the arrangement position of a first acoustic pressure sensor in a casting mold according to the present invention;
FIG. 4 is a flow chart of a method of the present invention for immersion three-dimensional ultrasonic metal solidification with controlled sound field;
FIG. 5A is a unidirectional ultrasonic sound pressure distribution diagram in a simulation experiment according to the present invention;
FIG. 5B is a graph of phi in a simulation experiment of the present invention1Is 0, phi2A sound pressure distribution diagram of a three-dimensional sound field at 0;
FIG. 5C is phi in the simulation experiment of the present invention1Is 0, phi2Is composed of
Sound pressure distribution diagram of time three-dimensional sound field;
FIG. 5D is a graph of phi in a simulation experiment of the present invention1Is composed of
φ2Is composed of
Sound pressure distribution diagram of time three-dimensional sound field;
FIG. 6A is a diagram of a distribution of cavitation zones in a unidirectional ultrasound field in a simulation experiment of the present invention;
FIG. 6B is a graph of phi in a simulation experiment of the present invention1Is 0, phi2A distribution diagram of cavitation zones in a three-dimensional sound field at 0;
FIG. 6C shows phi in the simulation experiment of the present invention1Is 0, phi2Is composed of
A distribution map of cavitation zones in the time three-dimensional sound field;
FIG. 6D is a graph of phi in a simulation experiment of the present invention1Is composed of
φ2Is composed of
Distribution diagram of cavitation area in three-dimensional sound field.
Description of reference numerals:
1-a stopper rod; 2-mother alloy pool; 3-casting a pipeline;
4, casting a mould; 5-an ultrasonic vibration component; 5-1-horn;
5-2-an ultrasound transducer; 6-displacement controller; 6-1-lead screw base;
6-2-lead screw; 6-3-lead screw nut; 6-4-motor;
7-a cooler; 7-1-cooling jacket; 7-2-a metal heat conducting agent;
7-3-heat resistant gasket; 7-4-outer gasket; 7-5-end cap;
8-second acoustic pressure sensor; 9- (c) -; a first sound pressure sensor 10-an acoustic signal acquisition circuit;
11-computer.
Detailed Description
As shown in FIG. 1, the immersion type three-dimensional ultrasonic metal solidification device with controllable sound field of the present embodiment comprises a metal solidification device body and a metal solidification data acquisition and controller, the metal solidifying apparatus body includes a casting mold 4 cast from the top and an ultrasonic vibration module 5 provided in a plurality of directions on the outer wall of the casting mold 4, the ultrasonic vibration component 5 comprises an ultrasonic transducer 5-2, an amplitude transformer 5-1 connected at the front end of the ultrasonic transducer 5-2 and a displacement controller 6 connected on the ultrasonic transducer 5-2 and used for driving the ultrasonic transducer 5-2 to move, the amplitude transformer 5-1 extends into the outer wall of the casting mould 4, a cooler 7 hermetically connected with the casting mould 4 and the amplitude transformer 5-1 is sleeved on the amplitude transformer 5-1, a master alloy pool 2 for heating and melting solid alloy raw materials and casting the solid alloy raw materials into the casting mould 4 is arranged above the casting mould 4;
the metal solidification data acquisition and controller comprises an acoustic signal acquisition circuit 10, a computer 11, a multi-path signal generator 12, a multi-path signal amplifier 13 and a sound pressure sensor group arranged in the casting mold 4, wherein the acoustic signal acquisition circuit, the computer 11, the multi-path signal generator 12, the multi-path signal amplifier 13 and the sound pressure sensor group are sequentially connected, the sound pressure sensor group comprises a plurality of first sound pressure sensors 9 arranged near the transmitting end of an amplitude transformer 5-1 in the casting mold 4 and used for measuring vibration sound pressure and a plurality of second sound pressure sensors 8 arranged in the casting mold 4 and used for measuring sound pressure distribution in a melt, and the first sound pressure sensors 9 and the second sound pressure sensors 8 are both connected with the acoustic signal acquisition circuit 10; the ultrasonic transducer 5-2 is connected with the output end of a multi-path signal amplifier 13, and the multi-path signal amplifier 13 is connected with the computer 11.
In specific implementation, the amplitude transformer 5-1 and the ultrasonic transducer 5-2 are in threaded connection.
In this embodiment, the casting mold 4 has a shape of a right quadrangular prism (the right quadrangular prism has four sides and a rectangular or square bottom surface), and the ultrasonic vibration unit 5 is disposed on three orthogonal directions of the outer wall of the casting mold 4.
In specific implementation, the number of the ultrasonic vibration assemblies 5 is three and the ultrasonic vibration assemblies are respectively arranged on 2 adjacent side surfaces and bottom surfaces.
In this embodiment, as shown in fig. 2, the displacement controller 6 includes a screw base 6-1, a screw 6-2 connected to the screw base 6-1, a screw nut 6-3 threadedly connected to the screw 6-2, and a motor 6-4 for driving the screw 6-2 to rotate, and the ultrasonic transducer 5-2 is connected to the screw nut 6-3.
During specific implementation, the motor 6-4 rotates to drive the screw rod 6-2 to rotate, the screw rod nut 6-3 moves back and forth on the screw rod 6-2 to drive the ultrasonic vibration assembly 5 to move back and forth, and the positions of the ultrasonic transducer 5-2 and the amplitude transformer 5-1 are adjusted.
In this embodiment, as shown in fig. 2, the cooler 7 includes a cooling jacket 7-1 which is sleeved on the amplitude transformer 5-1 and contains a cooling water channel 7-11 inside, a gap is left between an inner wall of the cooling jacket 7-1 and an outer wall of the amplitude transformer 5-1 and is filled with a metal heat conducting agent 7-2, a flange is arranged on one side of the cooling jacket 7-1 close to the casting mold 4 and is connected with an outer wall surface of the casting mold 4 through the flange, a heat-resistant sealing gasket 7-3 for sealing the gap between the amplitude transformer 5-1, the casting mold 4 and the cooling jacket 7-1 is arranged on one side of the cooling jacket 7-1, which is in contact with the casting mold 4, an outer sealing gasket 7-4 for sealing the metal heat conducting agent 7-2 is arranged on the other side of the cooling jacket 7-1, and an end cap 7-5 for pressing the outer sealing gasket 7-4 is fixedly connected to the cooling jacket 7-1.
In specific implementation, the cooling jacket 7-1 is fixedly connected with the outer wall surface of the casting mold 4 through a flange and a screw, and the end cover 7-5 is fixedly connected with the cooling jacket 7-1 through a screw.
In this embodiment, as shown in fig. 1, a casting pipe 3 connected to a casting mold 4 is connected to a bottom outflow hole of the master alloy pool 2, and a plug rod 1 capable of plugging the outflow hole is placed in the master alloy pool 2.
In this embodiment, as shown in fig. 3, the end surface of the horn 5-1 extending into the outer wall of the mold 4 is flush with the inner wall surface of the mold 4.
In this embodiment, the length L of the horn 5-1 satisfies the formula (to reduce loss) when the value is as small as possible
And satisfies the formula L1·η1+L2·η2>kL·(TL-Tc) (ii) a Wherein L is1The length, L, of the portion of the cooling device 7 which is sleeved on the amplitude transformer 5-12The length of the horn 5-1 exposed outside the cooler 7, m is a multiple coefficient and the value of m is a non-0 natural number, lambda is the ultrasonic wavelength in the horn 5-1, and k isLA value safety coefficient T of the length of the amplitude transformer 5-1LThe highest temperature of the melt in the casting mould 4, TcIs the failure temperature, eta, of the vibrating crystal inside the ultrasonic transducer 5-21The temperature drop coefficient, eta, of the cooler 7 part sleeved on the amplitude transformer 5-12The temperature drop coefficient of the exposed portion of the horn 5-1 outside the cooler 7 represents the value of the temperature drop per unit length along the heat transfer direction.
In specific practice, kLThe value range of (A) is 1.2-1.5.
In this embodiment, the number of the first sound pressure sensors 9 is equal to the number of the horns 5-1, the cross-sectional area of the probe of the first sound pressure sensor 9 is less than 10% of the cross-sectional area of the end of the horn 5-1, and the bottom surface of the probe of the first sound pressure sensor 9 is flush with the top surface extension surface of the horn 5-1 (the shielding of the first sound pressure sensor 9 on the vibration propagation of the horn 5-1 is reduced as much as possible); the number of the second sound pressure sensors 8 is 5-15. Each of the first sound pressure sensor 9 and the second sound pressure sensor 8 can independently transmit the sound pressure signal acquired by the first sound pressure sensor and the second sound pressure sensor to the sound signal acquisition circuit 10 through a cable and then to the computer 11.
In a specific implementation, the arrangement position of the first acoustic pressure sensor 9 in the casting mold 4 is shown in fig. 3.
As shown in fig. 4, the immersion type three-dimensional ultrasonic metal solidification method with controllable sound field of the present embodiment includes the following steps:
step one, alloy raw material loading: filling a multi-component alloy solid raw material into a master alloy pool 2;
in the embodiment, after the outflow hole is plugged by the plug rod 1, a multi-component alloy solid raw material is filled into the master alloy pool 2;
step two, installing a metal solidification device body: the displacement controller 6 drives the whole of the ultrasonic transducer 5-2, the amplitude transformer 5-1 and the cooler 7 to move towards the direction of the casting mold 4, so that the amplitude transformer 5-1 extends into the outer wall of the casting mold 4, and the end face of the amplitude transformer 5-1 extending into the outer wall of the casting mold 4 is flush with the inner wall face of the casting mold 4;
when the method is concretely implemented, cooling water is introduced into a cooling water channel 7-11 in the cooler 7;
step three, installing a sound pressure sensor: a first sound pressure sensor 9 is arranged near the transmitting end of each amplitude transformer 5-1, a plurality of second sound pressure sensors 8 are uniformly distributed in the casting mould 4, the first sound pressure sensors 9 and the second sound pressure sensors 8 are connected with a sound signal acquisition circuit 10, and target sound pressure values of the second sound pressure sensors 8 are input into a computer;
step four, setting an initial value of a vibration parameter: setting initial values of vibration parameters of the ultrasonic transducers 5-2, wherein the initial values of the vibration parameters comprise the amplitude and the vibration frequency of the ultrasonic transducers 5-2 and the phase difference among the ultrasonic transducers 5-2;
in specific implementation, the initial value of the vibration frequency is set as the resonance frequency of the ultrasonic transducer 5-2 at room temperature;
step five, smelting the master alloy: heating and melting the alloy solid raw material in the master alloy pool 2, and preserving heat;
in specific implementation, the heating adopts heating modes such as high-frequency induction heating, resistance furnace heating and the like; the heating temperature is required to be higher than the liquid state complete mixing and melting temperature by more than 100 ℃, and the temperature is kept for 30 min;
step six, melt pouring: pouring the melt in the master alloy pool 2 into a casting mould 4;
in the specific implementation, the plug rod 1 is removed, and the melt in the master alloy pool 2 flows into the casting mold 4 through the bottom outflow hole and the casting pipeline 3; in addition, under the condition that the casting pipeline 3 and the plug rod 1 are not arranged, a side-turning pouring mode can be adopted, and the melt in the master alloy pool 2 can be poured into the casting mould 4;
seventhly, performing wall surface vibration three-dimensional ultrasonic metal solidification under the feedback control of vibration frequency, phase and amplitude, wherein the concrete process is as follows:
step 701, the computer 11 sends a vibration frequency instruction and a phase difference instruction to the multi-channel signal generator 12 according to the initial value of the vibration parameter, and sends an amplitude instruction to the multi-channel signal amplifier 13; the electric signals sent by the multi-path signal generator 12 are transmitted to the multi-path signal amplifier 13, the signals amplified by the multi-path signal amplifier 13 are output to the ultrasonic transducer 5-2, the ultrasonic transducer 5-2 is driven, and the ultrasonic transducer 5-2 starts to vibrate according to the initial value of the vibration parameters; in the vibration process of the ultrasonic transducer 5-2, the first sound pressure sensor 9 acquires a sound pressure signal of each amplitude transformer 5-1, the second sound pressure sensor 8 acquires a sound pressure signal in a melt, the acquired sound pressure signals are transmitted to the sound signal acquisition circuit 10 through a cable and then transmitted to the computer 11, and the computer 11 compares the sound pressure signals acquired by the second sound pressure sensor 8 with a target sound pressure value to obtain a deviation evaluation value;
step 702, the computer 11 uses the vibration frequency of each ultrasonic transducer 5-2 as a regulation parameter at f0-△f～f0Changing a vibration frequency parameter within the value range of +/-af, vibrating the ultrasonic transducer 5-2 according to the vibration parameter after changing the vibration frequency, and changing the sound pressure value detected by the first sound pressure sensor 9; the computer 11 determines the vibration frequency parameter corresponding to the maximum sound pressure value in the whole value range of the vibration frequency parameter as the optimal vibration frequency parameter; wherein f is0Is the initial value of the vibration frequency (namely the resonance frequency of the ultrasonic transducer 5-2 at room temperature), and deltaf is the variation value of the vibration frequency;
in specific implementation, the value range of delta f is 1 kHz-5 kHz;
703, controlling the ultrasonic transducers 5-2 to vibrate by the computer 11 according to the optimal vibration frequency parameter, changing the phase difference parameter by taking the phase difference among the plurality of ultrasonic transducers 5-2 as a regulation parameter according to a set step length within a value range of 0-2 pi, and changing the deviation evaluation value of the ultrasonic transducers 5-2 according to the vibration parameter after changing the phase difference; the computer 11 determines a phase difference parameter corresponding to the minimum deviation evaluation value in the whole value range of the phase difference parameter as an optimal phase difference parameter;
step 704, the computer 11 controls the ultrasonic transducer 5-2 to vibrate according to the optimal vibration frequency and the optimal phase difference parameter, and a plurality of ultrasonic waves are generatedThe amplitude of the transducer 5-2 is used as a regulation parameter and is between 0 and AmaxIn the value range of (3), changing amplitude parameters according to a set step length, vibrating the ultrasonic transducer 5-2 according to the vibration parameters after changing the amplitude, and changing the deviation evaluation value; the computer 11 determines the amplitude parameter corresponding to the minimum deviation evaluation value in the whole value range of the amplitude parameter as the optimal amplitude parameter; wherein A ismaxThe maximum amplitude that the ultrasonic transducer 5-2 can reach;
step 705, the computer 11 displays the prompt that the optimal vibration frequency parameter, the optimal phase difference parameter and the optimal amplitude parameter are found;
step 706, the computer 11 controls the ultrasonic transducer 5-2 to vibrate according to the optimal vibration frequency parameter, the optimal phase difference parameter and the optimal amplitude parameter until the alloy melt is completely solidified;
step 707, turning off the ultrasonic transducer 5-2;
in the working process, the computer 11 displays the deviation evaluation value, the vibration frequency parameter, the phase difference parameter and the amplitude parameter in real time; the working personnel can find out the quality degrees of the vibration frequency parameter, the phase difference parameter and the amplitude parameter according to the displayed deviation evaluation value; the smaller the deviation evaluation value is, the better the corresponding vibration frequency parameter, phase difference parameter and amplitude parameter are.
Step eight, unloading the casting: and after the solid sample is cooled to the room temperature, unloading the ultrasonic vibration assembly 5, unloading the casting mold 4 and taking out the casting.
In this embodiment, the casting mold 4 is a rectangular prism (the rectangular prism has four side surfaces and a rectangular or square bottom surface), the number of the ultrasonic vibration assemblies 5 is three, and the three ultrasonic vibration assemblies are respectively an X-axis ultrasonic vibration assembly, a Y-axis ultrasonic vibration assembly and a Z-axis ultrasonic vibration assembly, and the X-axis ultrasonic vibration assembly, the Y-axis ultrasonic vibration assembly and the Z-axis ultrasonic vibration assembly are arranged in three orthogonal directions on the outer wall of the casting mold 4;
in the third step, the coordinate data of each second sound pressure sensor 8 is also input into the computer; the third step computer 11 records the target sound pressure value of the i-th second sound pressure sensor 8 as x in the form of an arrayi,yi,zi,S′i](ii) a In step seven, the computer 11 records the sound pressure value detected by the ith second sound pressure sensor 8 as [ x ] in an array formi,yi,zi,Si](ii) a Wherein x isiIs the X-axis coordinate value, y, of the ith second acoustic pressure sensor 8iIs the Y-axis coordinate value, z, of the ith second acoustic pressure sensor 8iIs a Z-axis coordinate value of the ith second sound pressure sensor 8, the value of i is a natural number from 1 to n, and n is the total number of the second sound pressure sensors 8, S'iIs a target sound pressure value, S, of the ith second sound pressure sensor 8iThe sound pressure value detected by the ith second sound pressure sensor 8;
the phase difference in the fourth step comprises the phase difference phi of the X-axis ultrasonic vibration component and the Y-axis ultrasonic vibration component1And the phase difference phi between the X-axis ultrasonic vibration component and the Z-axis ultrasonic vibration component2(ii) a Phase difference phi1And a phase difference phi2All initial values of (1) are 0; in step four, the amplitude includes the amplitude A of the X-axis ultrasonic vibration componentXAmplitude a of the Y-axis ultrasonic vibration assemblyYAnd amplitude A of Z-axis ultrasonic vibration assemblyZ(ii) a Amplitude AXHas an initial value of AX maxAmplitude AYHas an initial value of AY maxAmplitude AZHas an initial value of AZ max；AX maxMaximum amplitude, A, of the X-axis ultrasonic vibration assemblyY maxMaximum amplitude, A, of the Y-axis ultrasonic vibration assemblyZ maxThe maximum amplitude that can be achieved by the Z-axis ultrasonic vibration component; in step four, the vibration frequency comprises the vibration frequency f of the X-axis ultrasonic vibration componentXVibration frequency f of Y-axis ultrasonic vibration componentYAnd the vibration frequency f of the Z-axis ultrasonic vibration componentZ；
In specific implementation, f isXSet as the resonant frequency of the X-axis ultrasonic vibration component at room temperature, and fYSet as the resonant frequency of the Y-axis ultrasonic vibration component at room temperature, and fZSetting the resonant frequency of the Z-axis ultrasonic vibration component at room temperature;
the phase difference in steps 701 and 703 comprises an X-axis ultrasonic vibration component and a Y-axis ultrasonic vibration componentPhase difference phi of acoustic vibration component1And the phase difference phi between the X-axis ultrasonic vibration component and the Z-axis ultrasonic vibration component2(ii) a In step 703, the step size is
Within the value range of 0-2 pi, according to the set step length and the phase difference phi1And a phase difference phi2Form comprehensive values of the two-dimensional array are formed;
in particular, the two-dimensional array is represented as
The value of i 'is an integer from 0 to 32, and the value of j' is an integer from 0 to 32; i.e. to a value of [0,0]，[0,π/16]，[0,π/8],…，[0,2π],[π/16,0],…，[π/16,2π],……，[2π,15π/16]，[2π,2π]；
The amplitudes in steps 701 and 704 include the amplitude A of the X-axis ultrasonic vibration componentXAmplitude a of the Y-axis ultrasonic vibration assemblyYAnd amplitude A of Z-axis ultrasonic vibration assemblyZ(ii) a The step size in step 704 includes an amplitude AXStep size of variation 0.1AX maxAmplitude AYStep size of variation 0.1AY maxAmplitude AZStep size of variation 0.1AZ maxAmplitude AXIn the range of 0 to AX maxWithin a value range of (A), amplitude AYIn the range of 0 to AY maxWithin a value range of (A), amplitude AZIn the range of 0 to AZ maxAccording to a set step length and according to an amplitude AXAmplitude AYAnd amplitude AZForm comprehensive values of the three-dimensional array are formed;
in one embodiment, the amplitude parameter is represented as [ A ] in a three-dimensional arrayX,AY，AZ]＝[0.1i″AX max，0.1j″AY max，0.1z″AZ max]I ', j ', z ' are each independently integers of 0-10, i.e. the three-dimensional array takes on the value [ AX max,AY max,AZ max]、[AX max,AY max,0.9AZ max]…，[AX max,AY max,0]…，[0,0,0]；
The calculation formula of the deviation evaluation value sigma in steps 701, 703 and 704 is
Wherein, S'iIs a target sound pressure value, S, of the ith second sound pressure sensor 8iThe sound pressure value detected by the ith second sound pressure sensor 8;
in step 705, after the computer 11 displays a prompt that the optimal vibration frequency parameter, the optimal phase difference parameter, and the optimal amplitude parameter have been found, the worker moves out of the plurality of second sound pressure sensors 8.
In order to verify the technical effect of the immersion type three-dimensional ultrasonic metal solidification device and method with the controllable sound field, COMSOL software is used for carrying out simulation experiments, a casting mold 4 adopted in the experiments is a cube with the side length of 5cm, the casting mold material is 45# steel, a melt is Al-Si alloy, firstly, unidirectional ultrasonic simulation is carried out, and the obtained unidirectional ultrasonic sound pressure distribution diagram is shown in figure 5A; then, the vibration frequency f of the ultrasonic vibration component in the X axisXVibration frequency f of Y-axis ultrasonic vibration componentYAnd the vibration frequency f of the Z-axis ultrasonic vibration componentZAre all the optimal vibration frequency parameters; amplitude A of the X-axis ultrasonic vibration assemblyXAmplitude of the Y-axis ultrasonic vibration component and amplitude A of the Z-axis ultrasonic vibration componentZWhen the amplitudes of the phase difference values are all maximum amplitudes (10 mu m), sound pressure distribution calculation under the series of phase difference parameters is carried out to obtain phi1Is 0, phi2The sound pressure distribution diagram of the three-dimensional sound field at 0 is shown in FIG. 5B, and phi is obtained1Is 0, phi2Is composed of
The sound pressure distribution diagram of the time three-dimensional sound field is shown in FIG. 5C, and phi is obtained1Is composed of
φ2Is composed of
The sound pressure distribution diagram of the time three-dimensional sound field is shown in fig. 5D; according to the basic principle of the ultrasonic cavitation effect, when the sound pressure exceeds a cavitation threshold value, the cavitation effect can be generated, the solidification tissue of the material can be effectively regulated and controlled, the sound pressure data in the figures 5A-5D are subjected to cavitation region distribution statistics, and the obtained cavitation region distribution diagram in the unidirectional ultrasonic sound field is shown in figure 6A; to obtain phi1Is 0, phi2The distribution diagram of the cavitation region in the three-dimensional sound field at 0 is shown in FIG. 6B, and phi is obtained1Is 0, phi2Is composed of
The distribution diagram of the cavitation region in the time three-dimensional sound field is shown in FIG. 6C, and phi is obtained1Is composed of
φ2Is composed of
The distribution diagram of the cavitation region in the three-dimensional sound field is shown in FIG. 6D;
comparing fig. 5B to 5D with fig. 5A, it can be seen that, under the same amplitude condition, the sound pressure intensity generated by the uniaxially emitted ultrasound can generate a larger sound pressure at the emitting end, but the average value is very low in the whole space, and the sound pressure value in the melt can be greatly increased by adopting the multi-dimensional ultrasonic vibration; comparing fig. 5B-5D, it can be seen that vibrations of different phase differences can produce distinct sound pressure field characteristics; the phase difference parameter is regulated and controlled in the step 703 to seek the final phase difference parameter, which is very meaningful; the vibration frequency parameter is regulated and controlled in step 702, the phase difference parameter is regulated and controlled in step 703, and the amplitude parameter is regulated and controlled in step 704, so that the optimal vibration effect can be obtained.
Comparing fig. 6B to fig. 6D with fig. 6A, it can be seen that, under the condition of single-axis transmitted ultrasound, the cavitation volume is only 9.8%, and the tissue cannot be effectively regulated and controlled in most regions; and in the case of three-dimensional ultrasound, phi1Is 0, phi2Cavitation volume at 0 is 100% >, phi1Is 0,φ2Is composed of
The cavitation volume was 74.4%. phi. (phi.)1Is composed of
φ2Is composed of
The cavitation volume is 77.4%, the tissue can be effectively regulated and controlled in most areas, and the fine regulation and control of the cavitation area can be carried out according to actual requirements.
The above description is only a preferred embodiment of the present invention, and is not intended to limit the present invention, and all simple modifications, changes and equivalent structural changes made to the above embodiment according to the technical spirit of the present invention still fall within the protection scope of the technical solution of the present invention.
Claims (9)
1. The utility model provides a three-dimensional supersound metal solidification equipment of immersion of controllable sound field which characterized in that: the metal solidification device comprises a metal solidification device body and a metal solidification data acquisition and controller, wherein the metal solidification device body comprises a casting mold (4) poured from the top and ultrasonic vibration components (5) arranged on the outer wall of the casting mold (4) in multiple directions, each ultrasonic vibration component (5) comprises an ultrasonic transducer (5-2), an amplitude transformer (5-1) connected to the front end of the ultrasonic transducer (5-2) and a displacement controller (6) connected to the ultrasonic transducer (5-2) and used for driving the ultrasonic transducer (5-2) to move, the amplitude transformer (5-1) extends into the outer wall of the casting mold (4), a cooler (7) hermetically connected with the casting mold (4) and the amplitude transformer (5-1) is sleeved on the amplitude transformer (5-1), and a master alloy pool (2) used for heating and melting a solid alloy raw material and casting the casting mold (4) is arranged above the casting mold (4);
the metal solidification data acquisition and controller comprises an acoustic signal acquisition circuit (10), a computer (11), a multi-channel signal generator (12), a multi-channel signal amplifier (13) and a sound pressure sensor group arranged in a casting mold (4), wherein the acoustic signal acquisition circuit, the computer (11), the multi-channel signal generator (12), the multi-channel signal amplifier (13) and the sound pressure sensor group are sequentially connected, the sound pressure sensor group comprises a plurality of first sound pressure sensors (9) which are arranged near the transmitting end of an amplitude transformer (5-1) in the casting mold (4) and are used for measuring vibration sound pressure and a plurality of second sound pressure sensors (8) which are arranged in the casting mold (4) and are used for measuring sound pressure distribution in a melt, and the first sound pressure sensors (9) and the second sound pressure sensors (8) are both connected with the acoustic signal acquisition circuit (10); the ultrasonic transducer (5-2) is connected with the output end of a multi-path signal amplifier (13), and the multi-path signal amplifier (13) is connected with a computer (11);
the length L of the amplitude transformer (5-1) meets the formula under the condition of being as small as possible
And satisfies the formula L1·η1+L2·η2＞kL·(TL-Tc) (ii) a Wherein L is1The length of the part of the amplitude transformer (5-1) sleeved with the cooler (7), L2The length of the horn (5-1) exposed outside the cooler (7) is shown, m is a multiple coefficient, the value of m is a non-0 natural number, lambda is the ultrasonic wavelength in the horn (5-1), and k isLThe value of the safety coefficient T of the length of the amplitude transformer (5-1)LThe maximum temperature of the melt in the casting mould (4), TcIs the failure temperature, eta, of the vibrating crystal inside the ultrasonic transducer (5-2)1The temperature drop coefficient, eta, of the cooler (7) part sleeved on the amplitude transformer (5-1)2The temperature drop coefficient of the amplitude transformer (5-1) exposed outside the cooler (7) is shown.
2. The immersed three-dimensional ultrasonic metal solidification apparatus with a controlled sound field according to claim 1, wherein: the casting mould (4) is in a shape of a straight quadrangular prism, and the ultrasonic vibration component (5) is arranged on the outer wall of the casting mould (4) in three orthogonal directions.
3. The immersed three-dimensional ultrasonic metal solidification apparatus with a controlled sound field according to claim 1, wherein: the displacement controller (6) comprises a lead screw base (6-1), a lead screw (6-2) connected to the lead screw base (6-1), a lead screw nut (6-3) in threaded connection with the lead screw (6-2) and a motor (6-4) for driving the lead screw (6-2) to rotate, and the ultrasonic transducer (5-2) is connected to the lead screw nut (6-3).
4. The immersed three-dimensional ultrasonic metal solidification apparatus with a controlled sound field according to claim 1, wherein: the cooler (7) comprises a cooling jacket (7-1) which is sleeved on the amplitude transformer (5-1) and contains a cooling water channel (7-11) inside, a gap is reserved between the inner wall of the cooling jacket (7-1) and the outer wall of the amplitude transformer (5-1), a metal heat-conducting agent (7-2) is filled in the gap, a flange is arranged on one side, close to the casting mold (4), of the cooling jacket (7-1) and is connected with the outer wall surface of the casting mold (4) through the flange, a heat-resistant sealing gasket (7-3) used for sealing the gap among the amplitude transformer (5-1), the casting mold (4) and the cooling jacket (7-1) is arranged on one side, in contact with the casting mold (4), of the cooling jacket (7-1), and an outer sealing gasket (7-4) used for sealing the metal heat-conducting agent (7-2) is arranged on the other side of the cooling jacket (7-1), an end cover (7-5) used for compressing the outer sealing gasket (7-4) is fixedly connected to the cooling jacket (7-1).
5. The immersed three-dimensional ultrasonic metal solidification apparatus with a controlled sound field according to claim 1, wherein: a casting pipeline (3) communicated into the casting mold (4) is connected to a bottom outflow hole of the master alloy pool (2), and a plug rod (1) capable of plugging the outflow hole is placed in the master alloy pool (2).
6. The immersed three-dimensional ultrasonic metal solidification apparatus with a controlled sound field according to claim 1, wherein: the end surface of the amplitude transformer (5-1) extending into the outer wall of the casting mould (4) is flush with the inner wall surface of the casting mould (4).
7. The immersed three-dimensional ultrasonic metal solidification apparatus with a controlled sound field according to claim 1, wherein: the number of the first sound pressure sensors (9) is equal to that of the amplitude transformer (5-1), the cross sectional area of a probe of each first sound pressure sensor (9) is smaller than 10% of the cross sectional area of the end of the amplitude transformer (5-1), and the bottom surface of the probe of each first sound pressure sensor (9) is flush with the extended surface of the top surface of the amplitude transformer (5-1); the number of the second sound pressure sensors (8) is 5-15.
8. A method of controlled acoustic field, immersed three dimensional ultrasonic metal solidification using the metal solidification apparatus of claim 1, the method comprising the steps of:
step one, alloy raw material loading: filling a multi-component alloy solid raw material into a master alloy pool (2);
step two, installing a metal solidification device body: the displacement controller (6) drives the whole of the ultrasonic transducer (5-2), the amplitude transformer (5-1) and the cooler (7) to move towards the casting mold (4), so that the amplitude transformer (5-1) extends into the outer wall of the casting mold (4), and the end face of the amplitude transformer (5-1) extending into the outer wall of the casting mold (4) is flush with the inner wall face of the casting mold (4);
step three, installing a sound pressure sensor: a first sound pressure sensor (9) is arranged near the transmitting end of each amplitude transformer (5-1), a plurality of second sound pressure sensors (8) are uniformly distributed in the casting mould (4), the first sound pressure sensor (9) and the second sound pressure sensors (8) are connected with a sound signal acquisition circuit (10), and target sound pressure values of the second sound pressure sensors (8) are input into a computer;
step four, setting an initial value of a vibration parameter: setting initial values of vibration parameters of the ultrasonic transducers (5-2), wherein the initial values of the vibration parameters comprise the amplitude and the vibration frequency of the ultrasonic transducers (5-2) and the phase difference among the ultrasonic transducers (5-2);
step five, smelting the master alloy: heating and melting the alloy solid raw material in the master alloy pool (2), and preserving heat;
step six, melt pouring: pouring the melt in the master alloy pool (2) into a casting mould (4);
seventhly, performing wall surface vibration three-dimensional ultrasonic metal solidification under the feedback control of vibration frequency, phase and amplitude, wherein the concrete process is as follows:
step 701, the computer (11) sends a vibration frequency instruction and a phase difference instruction to the multi-channel signal generator (12) according to the initial value of the vibration parameter, and sends an amplitude instruction to the multi-channel signal amplifier (13); the electric signals sent by the multi-path signal generator (12) are transmitted to the multi-path signal amplifier (13), the signals amplified by the multi-path signal amplifier (13) are output to the ultrasonic transducer (5-2) to drive the ultrasonic transducer (5-2), and the ultrasonic transducer (5-2) starts to vibrate according to the initial value of the vibration parameters; in the vibration process of the ultrasonic transducer (5-2), a first sound pressure sensor (9) collects sound pressure signals of each amplitude transformer (5-1), a second sound pressure sensor (8) collects sound pressure signals in a melt, the collected sound pressure signals are transmitted to a sound signal collecting circuit (10) through a cable and then transmitted to a computer (11), and the computer (11) compares the sound pressure signals collected by the second sound pressure sensor (8) with a target sound pressure value to obtain a deviation evaluation value;
step 702, the computer (11) takes the vibration frequency of each ultrasonic transducer (5-2) as a regulation parameter at f0-Δf～f0Within the value range of + delta f, changing the vibration frequency parameter, vibrating the ultrasonic transducer (5-2) according to the vibration parameter after changing the vibration frequency, and changing the sound pressure value detected by the first sound pressure sensor (9); the computer (11) determines the vibration frequency parameter corresponding to the maximum sound pressure value in the whole value range of the vibration frequency parameter as the optimal vibration frequency parameter; wherein f is0The initial value of the vibration frequency is delta f, and the change value of the vibration frequency is delta f;
703, controlling the ultrasonic transducers (5-2) to vibrate by the computer (11) according to the optimal vibration frequency parameters, taking phase differences among the plurality of ultrasonic transducers (5-2) as regulation parameters, changing the phase difference parameters according to a set step length within a value range of 0-2 pi, vibrating the ultrasonic transducers (5-2) according to the vibration parameters after changing the phase differences, and changing deviation evaluation values; the computer (11) determines the phase difference parameter corresponding to the minimum deviation evaluation value in the whole value range of the phase difference parameter as the optimal phase difference parameter;
step 704, the computer (11) controls the ultrasonic transducers (5-2) to vibrate according to the optimal vibration frequency and the optimal phase difference parameter, and the amplitudes of the ultrasonic transducers (5-2) are used as regulation parameters and are controlled to be within the range of 0-AmaxAccording to the set step length, the amplitude parameter is changed, and the ultrasonic transducer (5-2) vibrates according to the changed amplitudeThe dynamic parameter vibrates, and the deviation evaluation value changes along with the dynamic parameter; the computer (11) determines the amplitude parameter corresponding to the minimum deviation evaluation value in the whole value range of the amplitude parameter as the optimal amplitude parameter; wherein A ismaxIs the maximum amplitude that the ultrasonic transducer (5-2) can reach;
step 705, the computer (11) displays the prompt that the optimal vibration frequency parameter, the optimal phase difference parameter and the optimal amplitude parameter are found;
step 706, controlling the ultrasonic transducer (5-2) to vibrate by the computer (11) according to the optimal vibration frequency parameter, the optimal phase difference parameter and the optimal amplitude parameter until the alloy melt is completely solidified;
step 707, turning off the ultrasonic transducer (5-2);
in the working process, the computer (11) displays the deviation evaluation value, the vibration frequency parameter, the phase difference parameter and the amplitude parameter in real time;
step eight, unloading the casting: and after the solid sample is cooled to room temperature, unloading the ultrasonic vibration assembly (5), unloading the casting mold (4) and taking out the casting.
9. The method of claim 8, wherein: the casting mold (4) is in a shape of a straight quadrangular prism, the number of the ultrasonic vibration assemblies (5) is three, the three ultrasonic vibration assemblies are respectively an X-axis ultrasonic vibration assembly, a Y-axis ultrasonic vibration assembly and a Z-axis ultrasonic vibration assembly, and the X-axis ultrasonic vibration assembly, the Y-axis ultrasonic vibration assembly and the Z-axis ultrasonic vibration assembly are arranged in three orthogonal directions of the outer wall of the casting mold (4);
in the third step, the coordinate data of each second sound pressure sensor (8) is also input into the computer; the computer (11) records the target sound pressure value of the ith second sound pressure sensor (8) as x in an array formi,yi,zi,S′i](ii) a In the seventh step, the computer (11) records the sound pressure value detected by the ith second sound pressure sensor (8) as [ x ] in an array formi,yi,zi,Si](ii) a Wherein x isiIs the X-axis coordinate value, y, of the ith second sound pressure sensor (8)iIs the Y-axis coordinate value, z, of the ith second sound pressure sensor (8)iIs as followsZ-axis coordinate values of i second sound pressure sensors (8), wherein the value of i is a natural number from 1 to n, and n is the total number of the second sound pressure sensors (8), S'iIs a target sound pressure value, S, of the ith second sound pressure sensor (8)iThe sound pressure value detected by the ith second sound pressure sensor (8);
the phase difference in the fourth step comprises the phase difference phi of the X-axis ultrasonic vibration component and the Y-axis ultrasonic vibration component1And the phase difference phi between the X-axis ultrasonic vibration component and the Z-axis ultrasonic vibration component2(ii) a Phase difference phi1And a phase difference phi2All initial values of (1) are 0; in step four, the amplitude includes the amplitude A of the X-axis ultrasonic vibration componentXAmplitude a of the Y-axis ultrasonic vibration assemblyYAnd amplitude A of Z-axis ultrasonic vibration assemblyZ(ii) a Amplitude AXHas an initial value of AXmaxAmplitude AYHas an initial value of AYmaxAmplitude AZHas an initial value of AZmax；AXmaxMaximum amplitude, A, of the X-axis ultrasonic vibration assemblyYmaxMaximum amplitude, A, of the Y-axis ultrasonic vibration assemblyZmaxThe maximum amplitude that can be achieved by the Z-axis ultrasonic vibration component; in step four, the vibration frequency comprises the vibration frequency f of the X-axis ultrasonic vibration componentXVibration frequency f of Y-axis ultrasonic vibration componentYAnd the vibration frequency f of the Z-axis ultrasonic vibration componentZ；
The phase difference in steps 701 and 703 includes a phase difference phi between the X-axis ultrasonic vibration component and the Y-axis ultrasonic vibration component1And the phase difference phi between the X-axis ultrasonic vibration component and the Z-axis ultrasonic vibration component2；
The amplitudes in steps 701 and 704 include the amplitude A of the X-axis ultrasonic vibration componentXAmplitude a of the Y-axis ultrasonic vibration assemblyYAnd amplitude A of Z-axis ultrasonic vibration assemblyZ(ii) a The step size in step 704 includes an amplitude AXStep size of variation 0.1AXmaxAmplitude AYStep size of variation 0.1AYmaxAmplitude AZStep size of variation 0.1AZmaxAmplitude AXIn the range of 0 to AXmaxWithin a value range of (A), amplitude AYIn the range of 0 to AYmaxWithin a value range of (A), amplitude AZIn the range of 0 to AZmaxAccording to a set step length and according to an amplitude AXAmplitude AYAnd amplitude AZForm comprehensive values of the three-dimensional array are formed;
the calculation formula of the deviation evaluation value sigma in steps 701, 703 and 704 is
Wherein, S'iIs a target sound pressure value, S, of the ith second sound pressure sensor (8)iThe sound pressure value detected by the ith second sound pressure sensor (8);
in step 705, after the computer (11) displays a prompt that the optimal vibration frequency parameter, the optimal phase difference parameter, and the optimal amplitude parameter have been found, the worker removes the plurality of second acoustic pressure sensors (8).
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| CN109317629B (en) * | 2018-11-22 | 2019-11-05 | 东北大学 | A kind of system and method using power ultrasound control continuous casting billet quality |
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