CN113231622A - Real-time regulated wall surface resonance ultrasonic metal solidification device and method - Google Patents

Real-time regulated wall surface resonance ultrasonic metal solidification device and method Download PDF

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CN113231622A
CN113231622A CN202110343508.1A CN202110343508A CN113231622A CN 113231622 A CN113231622 A CN 113231622A CN 202110343508 A CN202110343508 A CN 202110343508A CN 113231622 A CN113231622 A CN 113231622A
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vibration
ultrasonic
ultrasonic vibration
frequency
casting
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CN113231622B (en
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翟薇
王建元
胡亚杰
于洋
魏炳波
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Northwestern Polytechnical University
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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
    • B22D27/08—Shaking, vibrating, or turning of moulds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D2/00—Arrangement of indicating or measuring devices, e.g. for temperature or viscosity of the fused mass
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D2/00—Arrangement of indicating or measuring devices, e.g. for temperature or viscosity of the fused mass
    • B22D2/006—Arrangement of indicating or measuring devices, e.g. for temperature or viscosity of the fused mass for the temperature of the molten metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D46/00—Controlling, supervising, not restricted to casting covered by a single main group, e.g. for safety reasons

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  • Mechanical Engineering (AREA)
  • Apparatuses For Generation Of Mechanical Vibrations (AREA)
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Abstract

The invention discloses a real-time regulated wall surface resonance ultrasonic metal solidification device and a method, 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, an ultrasonic vibration assembly and a thrust rod; the method comprises the following steps: firstly, loading alloy raw materials; secondly, installing a metal solidification device body; thirdly, installing a sensor group; fourthly, setting an initial value of a vibration parameter; fifthly, searching the resonance frequency of the casting mould; sixthly, smelting the master alloy; seventhly, melt casting; eighthly, performing wall surface vibration three-dimensional ultrasonic metal solidification under the feedback control of vibration frequency; and ninthly, unloading the casting. The invention avoids the problem that the horn is in direct contact with the melt to cause overheating failure, solves the problems of low transmission efficiency and special hardware development cost, solves the problem that the ultrasonic vibration treatment effect is poor due to continuous change of a resonance point in the prior art, greatly improves the speed of searching the optimal vibration frequency, and realizes effective regulation and control of the solidification structure.

Description

Real-time regulated wall surface resonance ultrasonic metal solidification device and method
Technical Field
The invention belongs to the field of advanced material preparation and processing, and particularly relates to a real-time regulated wall surface resonance ultrasonic metal solidification device and method.
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, generally, a horn at an ultrasonic transmitting end is immersed in a melt to transmit ultrasonic waves, and the temperature of the horn is raised by heat transfer of the melt, so that the propagation sound velocity and the wavelength in 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 internal organization structure of the metal is changed, and plastic deformation or cracks occur, so that the horn is permanently failed, and therefore, the horn is not suitable for ultrasonic solidification of high-temperature metal.
(2) In the existing container vibration technology, a vibration amplitude transformer and the outer wall of a casting mold are generally connected by welding or other hard connection modes to form a new vibration system, but the resonance frequency of the new system is greatly deviated from the original working frequency of an ultrasonic transducer, so that the ultrasonic conduction efficiency is reduced or the ultrasonic transducer cannot work. Under the circumstance, a whole set of special vibration system needs to be developed specially aiming at different product shapes, and a universal ultrasonic transducer cannot be used, so that the cost is greatly increased.
(3) After the melt is injected into the casting mould, the temperature of the casting mould and the temperature of the amplitude transformer are increased, so that the resonance frequency of the system is deviated, and the resonance frequency is continuously changed along with the cooling and gradual solidification of the melt, so that the amplitude is reduced, and the ultrasonic vibration treatment effect is poor.
(4) In the prior art, actual sound pressure value detection in a melt is lacked, and the local vibration condition of a casting mold cannot truly reflect the superposition result of all wall vibration in the melt. This may result in failure to determine or search for optimal process parameters, thereby failing to achieve effective control of the coagulated tissue.
Disclosure of Invention
The technical problem to be solved by the invention is to provide a wall surface resonance ultrasonic metal solidification device capable of being regulated and controlled in real time aiming at the defects in the prior art, the design is novel and reasonable, the problem that an amplitude transformer is in direct contact with a melt to cause overheating failure is avoided, the problems of low transmission efficiency and special hardware development cost are solved, the problems of amplitude reduction and poor ultrasonic vibration treatment effect caused by continuous change of a resonance point in the prior art are solved, the speed of searching for the optimal vibration frequency is greatly improved, and the effective regulation and control of a solidification structure are realized.
In order to solve the technical problems, the invention adopts the technical scheme that: a real-time regulated wall surface resonance ultrasonic 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 an ultrasonic vibration assembly arranged for compressing the outer wall of the casting mold, and the outer wall of the casting mold is also provided with a thrust rod forming counter force with the ultrasonic vibration assembly to prevent the casting mold from moving; a melting crucible for melting the solid alloy raw materials and pouring the solid alloy raw materials into the casting mold is arranged above the casting mold;
the metal solidification data acquisition and control device comprises a sensor group, a signal acquisition circuit group, a computer, a variable frequency signal generator and a signal amplifier which are sequentially connected, wherein the sensor group comprises a vibration sensor arranged on the outer wall surface of the casting mould, and a temperature sensor and a sound pressure sensor which are arranged in the casting mould; the ultrasonic vibration component is connected with the output end of the signal amplifier, and the signal amplifier is connected with the computer.
In the above real-time controlled wall surface resonance ultrasonic metal solidification device, the spatial position relationship among the casting mold, the ultrasonic vibration component and the thrust rod is as follows: when the outer contour shape of the casting mould is a shape with parallel planes, the number of the thrust rods is one, and the thrust rods are arranged on the outer wall of the casting mould and on the plane opposite to the ultrasonic vibration component; when the outer contour shape of the casting mould is a shape without parallel planes, the number of the thrust rods is two, and the spatial position relationship between the ultrasonic vibration component and the two thrust rods meets the condition that any vertical plane separates the other two vertical planes at two sides of the vertical plane.
In the real-time controlled wall surface resonance ultrasonic metal solidification device, the optimal spatial position relationship among the casting mold, the ultrasonic vibration component and the thrust rod is determined by adopting a finite element simulation method, and the specific process comprises the following steps:
step A1, respectively carrying out size and material modeling on the casting mould, the ultrasonic vibration component and the thrust rod, and inputting corresponding material parameters;
step A2, selecting one of a plurality of feasible casting molds, the ultrasonic vibration component and the spatial position relation of the thrust rod, wherein the spatial position relation comprises the position and the direction of the contact point of the ultrasonic vibration component and the casting mold and the position and the direction of the contact point of the thrust rod and the casting mold;
step A3, establishing a connection relation and boundary conditions among a casting mould, an ultrasonic vibration component and a thrust rod, setting a friction coefficient among parts, setting the thrust rod to be fixed, setting a vibration function and vibration parameters of the ultrasonic vibration component, and dividing grids; the vibration parameters comprise amplitude and vibration frequency;
step A4, setting the total length and step length of time, carrying out simulation calculation of the vibration process, and checking the total vibration energy of the inner wall of the casting mold;
and step A5, changing the position and direction of the contact point of the ultrasonic vibration component and the casting mould and the position and direction of the contact point of the thrust rod and the casting mould for multiple times, repeatedly executing the steps A3-A4, finding the space position relation of the casting mould, the ultrasonic vibration component and the thrust rod corresponding to the maximum vibration total energy of the inner wall of the casting mould, and determining the space position relation as the optimal space position relation of the casting mould, the ultrasonic vibration component and the thrust rod.
According to the wall surface resonance ultrasonic metal solidification device capable of being regulated and controlled in real time, the smelting crucible is arranged right above the casting mold, the bottom of the smelting crucible is provided with the outflow hole through which the melt in the smelting crucible flows into the casting mold, and the smelting crucible is internally provided with the plug rod capable of plugging the outflow hole.
The ultrasonic vibration component comprises a sliding guide support, an ultrasonic transducer, an amplitude transformer and a cylinder for driving the ultrasonic transducer to move back and forth on the sliding guide support, the ultrasonic transducer is connected to the sliding guide support and can move back and forth on the sliding guide support, the ultrasonic transducer is connected with the output end of a signal amplifier, the amplitude transformer is connected to the front end of the ultrasonic transducer and is used for pressing the outer wall of a casting mold, the rear end of the ultrasonic transducer is connected with a pressure sensor, and the pressure sensor is connected with a piston push rod of the cylinder; the metal solidification data acquisition and controller further comprises a pressure recorder and an air pressure controller, the output end of the pressure sensor is connected with the input end of the pressure recorder, the output end of the pressure recorder is connected with the input end of the computer, the input end of the air pressure controller is connected with the output end of the computer, and the air cylinder is connected with the output end of the air pressure controller.
The ultrasonic vibration component comprises a sliding guide support, an ultrasonic transducer, an amplitude transformer and a power mechanism for driving the ultrasonic transducer to move back and forth on the sliding guide support, the ultrasonic transducer is connected to the sliding guide support and can move back and forth on the sliding guide support, the ultrasonic transducer is connected with the output end of a signal amplifier, the amplitude transformer is connected to the front end of the ultrasonic transducer and is used for pressing the outer wall of a casting mold, and the rear end of the ultrasonic transducer is connected with a pressure sensor 3-4; the power mechanism comprises a lead screw connecting seat, a lead screw connected to the lead screw connecting seat, a lead screw nut rotationally connected to the lead screw and a motor for driving the lead screw to rotate, the lead screw nut is connected with a vertical plate, and the pressure sensor is connected to the vertical plate; the metal solidification data acquisition and controller further comprises a pressure recorder and a motor driver, the output end of the pressure sensor is connected with the input end of the pressure recorder, the output end of the pressure recorder is connected with the input end of the computer, the input end of the motor driver is connected with the output end of the computer, and the motor is connected with the output end of the motor driver.
According to the wall surface resonance ultrasonic metal solidification device capable of being regulated and controlled in real time, the creep temperature T of the amplitude transformer is required to be met when the material of the amplitude transformer is selectedrHigher than the maximum temperature T of the outer surface of the casting mould 8 after castingw(ii) a The value of the length L of the amplitude transformer meets the formula under the condition of being as small as possible
Figure RE-GDA0003134991470000051
And satisfies the formula L > kL·(Tw-ΔTi-Tc) Eta,; wherein 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, delta TiFor transmitting temperature losses, T, between the mould and the horn headcThe failure temperature of the vibration crystal inside the ultrasonic transducer is shown as eta, and the temperature drop coefficient of the amplitude transformer is shown as eta.
The invention also discloses a method for wall surface resonance ultrasonic metal solidification, which solves the problems of low transmission efficiency and special hardware development cost, reduces the amplitude caused by continuous change of resonance points and deteriorates the ultrasonic vibration processing effect in the prior art, greatly improves the speed of searching the optimal vibration frequency, and realizes the multidirectional coupling real-time regulation and control of the solidification structure, and is characterized by comprising the following steps:
step one, alloy raw material loading: filling a multi-component alloy solid raw material into a melting crucible;
step two, installing a metal solidification device body: after the thrust rod is fixed, the outer wall of the casting mold 8 is firstly abutted against the thrust rod, and then the ultrasonic vibration component is tightly pressed on the outer wall of the casting mold;
step three, installing a sensor group: arranging a sound pressure sensor and a temperature sensor in a casting mold, arranging a vibration sensor on the outer wall surface of the casting mold, connecting the sound pressure sensor with a sound signal acquisition circuit, connecting the temperature sensor with a temperature signal acquisition circuit, and connecting the vibration sensor with the vibration signal acquisition circuit;
step four, setting an initial value of a vibration parameter: setting initial values of vibration parameters of the ultrasonic vibration component, wherein the initial values of the vibration parameters comprise extrusion force F, amplitude and vibration frequency of the ultrasonic vibration component;
step five, searching the resonance frequency of the casting mould, and the concrete process is as follows:
step 501, the computer sends a vibration frequency instruction to a variable frequency signal generator according to the initial value of the vibration parameter, an electric signal sent by the variable frequency signal generator is transmitted to a signal amplifier, the signal amplified by the signal amplifier is output to an ultrasonic vibration component to drive the ultrasonic vibration component, and the ultrasonic vibration component starts to vibrate according to the initial value of the vibration parameter; in the vibration process of the ultrasonic vibration component, the vibration sensor transmits the acquired vibration signal to the vibration signal acquisition circuit through a cable and then transmits the vibration signal to the computer, and the computer records the vibration signal;
step 502, the computer takes the vibration frequency as a regulation parameter, changes the vibration frequency parameter according to a set step length in a set vibration frequency value range, the ultrasonic vibration component vibrates according to the vibration parameter after changing the vibration frequency, and the vibration signal acquired by the vibration sensor changes accordingly; computingThe machine determines the vibration frequency parameter corresponding to the maximum vibration signal acquired by the vibration sensor in the whole value range of the vibration frequency parameter as the reference vibration frequency f0；
Step six, smelting the master alloy: heating and melting the alloy solid raw material in the melting crucible, and preserving heat;
step seven, melt pouring: pouring the melt in the melting crucible into a casting mold 8;
step eight, performing wall surface vibration three-dimensional ultrasonic metal solidification under the vibration frequency feedback control, wherein the concrete process is as follows:
step 801, adjusting the vibration frequency in the initial value of the vibration parameter to the reference vibration frequency f by the computer0Reference vibration frequency f0Sending the signal to a variable frequency signal generator, transmitting the electric signal sent by the variable frequency signal generator to a signal amplifier, outputting the signal amplified by the signal amplifier to an ultrasonic vibration component, driving the ultrasonic vibration component, and enabling the ultrasonic vibration component to vibrate according to a reference vibration frequency f0Starting vibration; in the vibration process of the ultrasonic vibration component, the temperature sensor transmits the acquired temperature signal to the temperature signal acquisition circuit through a cable and then transmits the temperature signal to the computer, the sound pressure sensor acquires a sound pressure signal in the melt, transmits the acquired sound pressure signal to the sound signal acquisition circuit through the cable and then transmits the sound pressure signal to the computer, and the computer records the sound pressure signal and the temperature signal;
step 802, the computer takes the vibration frequency as the regulation parameter again, at f0-Δf～f0Within the value range of + delta f, changing the vibration frequency according to the set step length, vibrating the ultrasonic vibration component according to the vibration parameter after changing the vibration frequency, and changing the sound pressure value detected by the sound pressure sensor; the computer determines the vibration frequency corresponding to the maximum sound pressure value in the whole value range of the vibration frequency as the optimal vibration frequency, and f0Updating the value of (a) to the optimal vibration frequency; wherein, Δ f is the value radius of the vibration frequency;
step 803, the computer repeatedly executes step 802, continuously searches for the optimal vibration frequency and enables the ultrasonic vibration component to vibrate according to the optimal vibration frequency;
and 804, when the temperature signal acquired by the temperature sensor is changed from the platform to be reduced along with the change of time, indicating that the alloy melt is nearly completely solidified, and closing the ultrasonic vibration assembly.
Step nine, unloading the casting: and after the solid sample is cooled to room temperature, unloading the ultrasonic vibration assembly and the thrust rod, unloading the casting mold, and taking out the casting.
In the method, the vibration frequency range in step 502 is 20kHz to 100 kHz; the step size is 0.1 kHz.
In the method, the extrusion force F in the step four is determined by adopting a vibration experiment of an ultrasonic vibration component, and the specific process is as follows:
step B1, installing a metal solidification device according to the method from the first step to the third step;
step B2, inquiring the yield strength of the material used for the casting mould at the temperature when the melt is poured into the casting mould and the yield strength of the material used for the ultrasonic vibration component at the highest temperature of the outer surface of the casting mould after casting in a material parameter table, and taking the smaller value of the two values as sigmas；
Step B3, determining the value range of the extrusion force F to be 10 Newton-KFσsS Newton, wherein KFIn order to obtain the value safety coefficient of the extrusion force, S is the contact area of the ultrasonic vibration component 3 and the casting mold 8;
step B4, setting the amplitude of the ultrasonic vibration component as the maximum amplitude, setting the vibration frequency as the resonance frequency, starting the single ultrasonic vibration component, sending the maximum amplitude instruction to a signal amplifier by the computer, outputting the signal amplified by the signal amplifier to the ultrasonic vibration component, driving the ultrasonic vibration component, and starting the ultrasonic vibration component to vibrate; in the vibration process of the ultrasonic vibration component, the power is 10 Newton-KFσsChanging the value of the extrusion force F for multiple times within the value range of S Newton, collecting the sound pressure value detected by the sound pressure sensor by the computer, recording the change of the sound pressure U along with the change of the extrusion force F as U, and recording the change of the sound pressure U along with the change of the extrusion force F according to the U as U0[1-exp(-F/f0)]Performing curve fitting to obtain characteristic parameter f of extrusion force0(ii) a Wherein, U0Is saturated soundPressing;
step B5, compare kff0And KFσsSize of S, will kff0And KFσsDetermining the smaller value of S as the optimal value of the extrusion force F; wherein k isfIs a characteristic coefficient; kFThe value safety coefficient of the extrusion force is obtained.
Compared with the prior art, the invention has the following advantages:
1. the ultrasonic vibration component is tightly pressed on the outer wall of the casting mould component, namely, a wall surface vibration mode is adopted, so that the problem that the amplitude transformer is directly contacted with a melt to cause overheating failure is solved; and the service life of the equipment is prolonged, and a better ultrasonic treatment effect is realized.
2. The invention adopts the mode of combining the ultrasonic vibration component and the thrust rod, adopts extrusion force to install the vibration system, optimizes the position layout and the extrusion force, can realize high-efficiency vibration propagation and ultrasonic solidification of the casting molds with different shapes by adopting the same hardware system, and simultaneously solves the problems of low transmission efficiency and special hardware development cost.
3. Before a melt is injected into a casting mold, a vibration sensor is adopted to detect the vibration amplitude, and the frequency is scanned according to the signal to search the reference vibration frequency; after the melt is injected into the casting mold, the sound pressure sensor is adopted to continuously detect the sound pressure in the melt, the frequency is scanned according to the signal, the resonance point of the system is tracked, and the optimal vibration frequency is searched, so that the problems that in the prior art, the amplitude is reduced and the ultrasonic vibration treatment effect is poor due to continuous change of the resonance point are solved.
4. The invention reduces the searching range when searching the optimal vibration frequency to be near the reference vibration frequency by searching the reference vibration frequency, greatly improves the speed of searching the optimal vibration frequency and avoids the searching speed from failing to meet the requirement of the solidification speed.
5. The invention adopts the signal collected by the sound pressure sensor as the reference to judge the vibration state of the melt, thereby searching the optimal vibration frequency in real time, solving the problem of inaccurate judgment of the vibration effect when detecting the sound pressure through the local vibration condition of the casting mould in the prior art and realizing the effective regulation and control of the solidification structure.
In conclusion, the invention avoids the problem that the amplitude transformer is overheated and fails due to direct contact with the melt, solves the problems of low transmission efficiency and special hardware development cost, solves the problems of amplitude reduction and poor ultrasonic vibration treatment effect caused by continuous change of resonance points in the prior art, greatly improves the speed of searching the optimal vibration frequency, and realizes effective regulation and control of the solidification structure.
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 a real-time controlled wall-resonance ultrasonic metal solidification device in embodiment 1 of the present invention;
FIG. 2A is a schematic structural view of a mold having a pentagonal prism shaped outer profile according to the present invention;
FIG. 2B is a schematic view of a first arrangement of thrust rods according to the present invention when the mold is the configuration of FIG. 2A;
FIG. 2C is a schematic view of a second arrangement of thrust rods according to the present invention when the mold is the configuration of FIG. 2A;
FIG. 2D is a diagram of a vibration condition obtained by performing finite element simulation on the layout position of the thrust rod shown in FIG. 2B;
FIG. 2E is a diagram of a vibration condition obtained by performing finite element simulation on the layout position of the thrust rod shown in FIG. 2C;
FIG. 2F is a graph of the dynamic variation of the total energy resulting from summing the vibrational energy of the various facets;
FIG. 3 is a schematic structural diagram of a real-time controlled wall-resonance ultrasonic metal solidification device in embodiment 2 of the present invention;
FIG. 4 is a flow field diagram of the method of the present invention for real-time controlled wall resonance ultrasonic metal solidification;
FIG. 5A is an external view of the vibration process in a vibration simulation experiment according to the present invention;
FIG. 5B is a graph of test results from a vibration simulation experiment according to the present invention;
FIG. 5C is a graph of the optimum frequency search result of the metal solidification process of the vibration simulation experiment of the present invention;
FIG. 5D is a statistical chart of the optimum frequency of the metal solidification process in the vibration simulation experiment of the present invention.
Description of reference numerals:
1-a variable frequency signal generator; 2-a signal amplifier; 3-an ultrasonic vibration assembly;
4-a thrust rod; 5-a vibration sensor; 6-temperature sensor;
7-a sound pressure sensor; 8, casting a mould; 9-vibration signal acquisition circuit;
10-an acoustic signal acquisition circuit; 11-temperature signal acquisition circuit; 12-a stopper rod;
13-melting crucible; 14-a computer; 15-thrust rod fixing frame;
16-a first three-dimensional mobile station; 17-a second three-dimensional mobile station; 3-1-horn;
3-2-an ultrasound transducer; 3-sliding guide support; 3-4-pressure sensor;
3-5-cylinder; 3-6-piston push rod; 3-7-pressure recorder;
3-8-air pressure controller; 3-9-cylinder support; 3-10-lead screw connecting base;
3-11-lead screw; 3-12-lead screw nut; 3-13-vertical plate;
3-14-motor drive; 3-15-motor; 3-31-base;
3-32-guide bar; 3-33-sliding block.
Detailed Description
Example 1
As shown in fig. 1, the real-time controlled wall surface resonance ultrasonic metal solidification device of the present embodiment includes a metal solidification device body and a metal solidification data acquisition and controller, the metal solidification device body includes a casting mold 8 poured from the top and an ultrasonic vibration component 3 arranged to press the outer wall of the casting mold 8, the outer wall of the casting mold 8 is further provided with a thrust rod 4 forming a counter force with the ultrasonic vibration component 3 to prevent the casting mold 8 from moving; a melting crucible 13 for melting the solid raw materials of the alloy and pouring the solid raw materials into the casting mold 8 is arranged above the casting mold 8;
the metal solidification data acquisition and control device comprises a sensor group, a signal acquisition circuit group, a computer 14, a variable frequency signal generator 1 and a signal amplifier 2 which are sequentially connected, wherein the sensor group comprises a vibration sensor 5 arranged on the outer wall surface of a casting mold 8, a temperature sensor 6 and a sound pressure sensor 7 which are arranged in the casting mold 8, the signal acquisition circuit group comprises a vibration signal acquisition circuit 9, a temperature signal acquisition circuit 11 and a sound signal acquisition circuit 10, the vibration sensor 5 is connected with the vibration signal acquisition circuit 9, the temperature sensor 6 is connected with the temperature signal acquisition circuit 11, and the sound pressure sensor 7 is connected with the sound signal acquisition circuit 10; the ultrasonic vibration component 3 is connected with the output end of the signal amplifier 2, and the signal amplifier 2 is connected with the computer 14.
In specific implementation, the temperature sensor 6 is a thermocouple, the thrust rod 4 is fixedly connected to a thrust rod fixing frame 15, the sound pressure sensor 7 is installed on a first three-dimensional moving platform 16, and the temperature sensor 6 is installed on a second three-dimensional moving platform 17.
In this embodiment, the spatial position relationship among the mold 8, the ultrasonic vibration component 3 and the thrust rod 4 is as follows: when the outer contour shape of the casting mold 8 is a shape with parallel facing planes, the number of the thrust rods 4 is one and the thrust rods are arranged on the plane of the outer wall of the casting mold 8 facing the ultrasonic vibration component 3; when the outer contour shape of the casting mold 8 is a shape without parallel planes facing each other, the number of the thrust rods 4 is two, and the spatial position relationship between the ultrasonic vibration component 3 and the two thrust rods 4 satisfies that a vertical plane on which any one exists divides the other two sides of the vertical plane.
For example, fig. 2A shows a mold 8 with a pentagonal prism outer profile, and the thrust rods 4 are arranged as shown in fig. 2B (under two adjacent thrust rods) and fig. 2C (under two spaced thrust rods).
In this embodiment, the casting mold 8 is formed by butt-jointing a left half casting mold and a right half casting mold, the outer contour of the casting mold 8 is a right quadrangular prism (the right quadrangular prism has four side surfaces and a rectangular or square bottom surface), the ultrasonic vibration component 3 is disposed at the center position of the outer wall surface of the left half casting mold or the right half casting mold, and the thrust rod 4 is disposed at a position opposite to the ultrasonic vibration component 3. That is, when the ultrasonic vibration module 3 is disposed at the center position of the left mold half outer wall surface, the thrust rod 4 is disposed at the center position of the right mold half outer wall surface; when the ultrasonic vibration module 3 is disposed at the center position of the right mold half outer wall surface, the thrust rod 4 is disposed at the center position of the left mold half outer wall surface. The inner contour of the casting mold 8 is in a quadrangular prism shape (other shapes such as a cylindrical shape can be adopted); the cross sections of the side wall and the bottom wall of the left half casting mold are provided with extended positioning pins, the cross sections of the side wall and the bottom wall of the right half casting mold are provided with positioning holes for the insertion of the positioning pins, and the left half casting mold and the right half casting mold are in butt joint to form a casting mold 8 in a mode that the positioning pins are inserted into the positioning holes.
In this embodiment, the casting mold 8 is made of a material having high strength and toughness, such as alloy steel, cast iron, graphite, and ceramic.
In addition, in practical implementation, when the outer contour of the mold 8 is in a shape with parallel facing planes, the position and the direction of the contact point between the thrust rod 4 and the mold 8 are easily determined, and the contact point is arranged on the outer wall of the mold 8 in the plane facing the ultrasonic vibration component 3, and the direction is perpendicular to the outer wall of the mold 8, or perpendicular to the tangent line of the outer wall of the mold 8.
In this embodiment, the optimal spatial position relationship among the mold 8, the ultrasonic vibration component 3, and the thrust rod 4 is determined by a finite element simulation method, and the specific process is as follows:
step A1, modeling the size and the material of the casting mould 8, the ultrasonic vibration component 3 and the thrust rod 4 respectively, and inputting corresponding material parameters;
in specific implementations, the material parameters include density, modulus of elasticity, poisson's ratio, damping, and plasticity;
step a2, selecting one of a plurality of possible spatial positional relationships of the mold 8, the ultrasonic vibration assembly 3, and the thrust rod 4, the spatial positional relationship including the position and orientation of the contact point of the ultrasonic vibration assembly 3 with the mold 8, and the position and orientation of the contact point of the thrust rod 4 with the mold 8;
step A3, establishing a connection relation and boundary conditions among the casting mold 8, the ultrasonic vibration component 3 and the thrust rod 4, setting friction coefficients among parts, setting the thrust rod 4 to be fixed, setting a vibration function (such as a sine function) and vibration parameters of the ultrasonic vibration component 3, and dividing grids; the vibration parameters comprise amplitude and vibration frequency;
step A4, setting the total length of time and the step length, carrying out simulation calculation on the vibration process, and checking the total vibration energy of the inner wall of the casting mold 8;
in specific implementation, the total time length is set to be
Figure RE-GDA0003134991470000121
Step size of
Figure RE-GDA0003134991470000122
f is the vibration frequency of the ultrasonic vibration component 3;
and step A5, changing the position and direction of the contact point of the ultrasonic vibration component 3 and the casting mould 8 and the position and direction of the contact point of the thrust rod 4 and the casting mould 8 for multiple times, and repeatedly executing the steps A3-A4 to find the space position relation of the casting mould 8, the ultrasonic vibration component 3 and the thrust rod 4 corresponding to the maximum vibration total energy of the inner wall of the casting mould 8 and determine the space position relation as the optimal space position relation of the casting mould 8, the ultrasonic vibration component 3 and the thrust rod 4.
In specific implementation, ABAQUS software is adopted to carry out finite element simulation.
For example, a finite element simulation is performed on the arrangement position of the thrust rod 4 shown in fig. 2B by using the mold 8 with the outer profile in the shape of a pentagonal prism as shown in fig. 2A, and the obtained vibration situation diagram is shown in fig. 2D; finite element simulation is carried out on the arrangement position of the thrust rod 4 shown in FIG. 2C, and the obtained vibration condition diagram is shown in FIG. 2E; as shown in fig. 2F, when the total vibration energy of the two thrust rods 4 in the case of fig. 2B (in the case of the two thrust rods adjacent to each other) is significantly higher than the total vibration energy in the case of fig. 2C (in the case of the two thrust rods spaced apart from each other) and is not higher than the total vibration energy in the case of fig. 2B (in the case of the two thrust rods adjacent to each other), the dynamic change of the total vibration energy can be obtained by summing the vibration energies of the respective surfaces, and as can be seen from fig. 2F, fig. 2B (in the case of the two thrust rods adjacent to each other) is the optimal position.
According to the invention, by adopting a finite element simulation method and determining the optimal spatial position relationship among the casting mold 8, the ultrasonic vibration component 3 and the thrust rod 4 according to the highest total vibration energy, the setting mode of the thrust rod 4 with the best vibration effect can be found out.
In the present embodiment, the melting crucible 13 is disposed directly above the casting mold 8, the bottom of the melting crucible 13 is provided with a discharge hole through which the melt in the melting crucible 13 flows into the casting mold 8, and the stopper rod 12 capable of closing the discharge hole is disposed in the melting crucible 13.
In the embodiment, the ultrasonic vibration component 3 comprises a sliding guide support 3-3, an ultrasonic transducer 3-2, an amplitude transformer 3-1 and a cylinder 3-5 for driving the ultrasonic transducer 3-2 to move back and forth on the sliding guide support 3-3, the ultrasonic transducer 3-2 is connected to the sliding guide support 3-3 and can move back and forth on the sliding guide support 3-3, the ultrasonic transducer 3-2 is connected with the output end of the signal amplifier 2, the amplitude transformer 3-1 is connected with the front end of the ultrasonic transducer 3-2 and is used for compacting the outer wall of the casting mould 8, the rear end of the ultrasonic transducer 3-2 is connected with a pressure sensor 3-4, and the pressure sensor 3-4 is connected with a piston push rod 3-6 of a cylinder 3-5; the metal solidification data acquisition and controller further comprises a pressure recorder 3-7 and an air pressure controller 3-8, the output end of the pressure sensor 3-4 is connected with the input end of the pressure recorder 3-7, the output end of the pressure recorder 3-7 is connected with the input end of the computer 14, the input end of the air pressure controller 3-8 is connected with the output end of the computer 14, and the air cylinder 3-5 is connected with the output end of the air pressure controller 3-8.
In specific implementation, the amplitude transformer 3-1 is in threaded connection with the ultrasonic transducer 3-2, and the cylinder 3-5 is mounted on the cylinder support 3-9. The computer 14 controls the air flow mode and the air pressure in the air cylinder 3-5 through the air pressure controller 3-8, can control the movement of the piston push rod 3-6, the front pressure sensor 3-4, the ultrasonic transducer 3-2 and the amplitude transformer 3-1, adjust the extrusion force of the ultrasonic vibration component 3 on the casting mold 8, detect the extrusion force through the pressure sensor 3-4, and transmit the extrusion force to the computer 14 through the pressure recorder 3-7; by arranging the pressure sensors 3-4, the pressure recorder 3-7 and the air pressure controller 3-8, the ultrasonic vibration component 3 can be guaranteed to be pressed against the outer wall of the casting mold 8 at a certain pressure value all the time.
In specific implementation, the sliding guide support 3-3 comprises a base 3-31 and a guide rod 3-32 connected to the base 3-31, a sliding block 3-33 is connected to the guide rod 3-32 in a sliding manner, and the ultrasonic transducer 3-2 is fixedly connected to the top of the sliding block 3-33.
In this embodiment, the material of the horn 3-1 is selected to satisfy the creep temperature T of the horn 3-1rHigher than the maximum temperature T of the outer surface of the casting mould 8 after castingw(ii) a The length L of the amplitude transformer 3-1 meets the formula under the condition of being as small as possible (so as to reduce loss)
Figure RE-GDA0003134991470000141
And satisfies the formula L > kL·(Tw-ΔTi-Tc) Eta,; wherein m is a multiple coefficient, the value of m is a non-0 natural number, lambda is the ultrasonic wavelength in the amplitude transformer 3-1, and k isLA value safety coefficient, delta T, of the length of the amplitude transformer 3-1iFor transmitting temperature loss, T, between the mould 8 and the head of the horn 3-1cFor failure temperature of vibrating crystal inside ultrasonic transducer 3-2And eta is a temperature drop coefficient of the horn 3-1, which represents a value of a temperature drop per unit length along the heat transfer direction.
In specific implementation, the maximum temperature T of the outer surface of the casting mold 8 after casting is measured through experimentswThe creep temperature T of the horn 3-1 can be determinedrThen according to the creep temperature T of the horn 3-1rSelecting a proper material to manufacture the amplitude transformer 3-1; k is a radical ofLThe value range of (A) is 1.2-1.5.
The method for real-time regulation and control of wall surface resonance ultrasonic metal solidification in the embodiment comprises the following steps:
step one, alloy raw material loading: filling a multi-component alloy solid raw material into a melting crucible 13;
in the embodiment, after the outflow hole is plugged by the plug rod 12, a multi-component alloy solid raw material is loaded into the melting crucible 13;
step two, installing a metal solidification device body: after the thrust rod 4 is fixed (fixed on a desktop or other fixing devices), the outer wall of the casting mold 8 is firstly abutted against the thrust rod 4, and then the ultrasonic vibration component 3 is tightly pressed on the outer wall of the casting mold 8;
in the embodiment, when the ultrasonic vibration component 3 is installed, the air pressure and the air inlet direction of the air cylinder 3-5 are adjusted, so that the amplitude transformer 3-1 is pressed against the outer wall of the casting mold 8;
step three, installing a sensor group: arranging a sound pressure sensor 7 and a temperature sensor 6 in a casting mould 8, arranging a vibration sensor 5 on the outer wall surface of the casting mould 8, connecting the sound pressure sensor 7 with a sound signal acquisition circuit 10, connecting the temperature sensor 6 with a temperature signal acquisition circuit 11, and connecting the vibration sensor 5 with a vibration signal acquisition circuit 9;
step four, setting an initial value of a vibration parameter: setting initial values of vibration parameters of the ultrasonic vibration component 3, wherein the initial values of the vibration parameters comprise extrusion force F, amplitude and vibration frequency of the ultrasonic vibration component 3;
in this embodiment, in step four, the extrusion force F is determined by a vibration experiment of the ultrasonic vibration component 3, and the specific process is as follows:
step B1, installing a metal solidification device according to the method from the first step to the third step;
step B2, inquiring the yield strength of the material used for the casting mold 8 at the temperature when the melt is poured into the casting mold 8 and the yield strength of the material used for the ultrasonic vibration component 3 at the highest temperature of the outer surface of the casting mold 8 after casting in the material parameter table, and taking the smaller value of the two values as sigmas；
Step B3, determining the value range of the extrusion force F to be 10 Newton-KFσsS Newton, wherein KFIn order to obtain the value safety coefficient of the extrusion force, S is the contact area of the ultrasonic vibration component 3 and the casting mold 8;
step B4, setting the amplitude of the ultrasonic vibration component 3 as the maximum amplitude, the vibration frequency as the resonance frequency, starting the single ultrasonic vibration component 3, sending the maximum amplitude instruction to the signal amplifier 2 by the computer 14, outputting the signal amplified by the signal amplifier 2 to the ultrasonic vibration component 3, driving the ultrasonic vibration component 3, and starting the ultrasonic vibration component 3 to vibrate; the vibration process of the ultrasonic vibration component 3 is 10 Newton-KFσsChanging the value of the extrusion force F for a plurality of times within the range of S newtons, collecting the sound pressure value detected by the sound pressure sensor 7 by the computer 14, recording the change of the sound pressure U along with the change of the extrusion force F as U, and recording the change of the sound pressure U along with the change of the extrusion force F according to the result that the change of the sound pressure U is equal to U0[1-exp(-F/f0)]Performing curve fitting to obtain characteristic parameter f of extrusion force0(ii) a Wherein, U0Saturated sound pressure;
step B5, compare kff0And KFσsSize of S, will kff0And KFσsDetermining the smaller value of S as the optimal value of the extrusion force F; wherein k isfThe value range is 2-4 for the characteristic coefficient; kFThe value safety coefficient of the extrusion force is obtained.
In specific practice, KFIs 0.8. When k isfIs 3, and the optimal value of the extrusion force F is 3F0In time, the sound pressure U can reach the saturated sound pressure U0More than 95%.
Step five, searching the resonance frequency of the casting mould, and the concrete process is as follows:
step 501, the computer 14 sends a vibration frequency instruction to the variable frequency signal generator 1 according to the initial value of the vibration parameter, an electric signal sent by the variable frequency signal generator 1 is transmitted to the signal amplifier 2, a signal amplified by the signal amplifier 2 is output to the ultrasonic vibration component 3 to drive the ultrasonic vibration component 3, and the ultrasonic vibration component 3 starts to vibrate according to the initial value of the vibration parameter; in the vibration process of the ultrasonic vibration component 3, the vibration sensor 5 transmits the acquired vibration signal to the vibration signal acquisition circuit 9 through a cable, and then transmits the vibration signal to the computer 14, and the computer 14 records the vibration signal;
step 502, the computer 14 uses the vibration frequency as a regulation parameter, changes the vibration frequency parameter according to a set step length in a set vibration frequency value range, the ultrasonic vibration component 3 vibrates according to the vibration parameter after changing the vibration frequency, and the vibration signal collected by the vibration sensor 5 changes accordingly; the computer 14 determines the vibration frequency parameter corresponding to the maximum vibration signal acquired by the vibration sensor 5 in the whole value range of the vibration frequency parameter as the reference vibration frequency f0；
In this embodiment, the vibration frequency range in step 502 is 20kHz to 100 kHz; the step size is 0.1 kHz.
Step six, smelting the master alloy: heating and melting the alloy solid raw material in the melting crucible 13, 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 seven, melt pouring: pouring the melt in the melting crucible 13 into the casting mold 8;
in the specific implementation, the plug rod 12 is removed, and the melt in the melting crucible 13 flows into the casting mold 8 through the bottom outflow hole; in addition, under the condition that the plug rod 12 is not arranged, a side-turning pouring mode can be adopted, and the melt in the melting crucible 13 can be poured into the casting mold 8;
step eight, performing wall surface vibration three-dimensional ultrasonic metal solidification under the vibration frequency feedback control, wherein the concrete process is as follows:
step 801, countingThe computer 14 adjusts the vibration frequency of the initial value of the vibration parameter to a reference vibration frequency f0Reference vibration frequency f0Sending the signals to a variable frequency signal generator 1, transmitting the electric signals sent by the variable frequency signal generator 1 to a signal amplifier 2, outputting the signals amplified by the signal amplifier 2 to an ultrasonic vibration component 3, driving the ultrasonic vibration component 3, and enabling the ultrasonic vibration component 3 to vibrate according to a reference vibration frequency f0Starting vibration; in the vibration process of the ultrasonic vibration component 3, the temperature sensor 6 transmits the acquired temperature signal to the temperature signal acquisition circuit 11 through a cable and then to the computer 14, the sound pressure sensor 7 acquires a sound pressure signal in the melt, transmits the acquired sound pressure signal to the sound signal acquisition circuit 10 through a cable and then to the computer 14, and the computer 14 records the sound pressure signal and the temperature signal;
step 802, the computer 14 uses the vibration frequency as the control parameter again, at f0-Δf～f0Within the value range of + Δ f, the vibration frequency is changed according to the set step length, the ultrasonic vibration component 3 vibrates according to the vibration parameter after the vibration frequency is changed, and the sound pressure value detected by the sound pressure sensor 7 is changed accordingly; the computer 14 determines the vibration frequency corresponding to the maximum sound pressure value in the whole value range of the vibration frequency as the optimal vibration frequency, and determines f0Updating the value of (a) to the optimal vibration frequency; wherein, Δ f is the value radius of the vibration frequency;
in specific implementation, the value range of delta f is 1 kHz-5 kHz; the step size is 10 Hz.
Step 803, the computer 14 repeatedly executes step 802, continuously searches for the optimal vibration frequency and makes the ultrasonic vibration component 3 vibrate according to the optimal vibration frequency;
and step 804, when the temperature signal acquired by the temperature sensor 6 changes from a platform to a descending state along with the change of time (namely, when the horizontal platform of the temperature curve is finished), indicating that the alloy melt is nearly completely solidified, and closing the ultrasonic vibration component 3 at the moment.
Since the temperature will remain at a fixed value during the solidification of the alloy melt, and the temperature will decrease when the alloy melt is close to complete solidification, the temperature signal is used as an indication for detecting that the alloy melt is close to complete solidification, and in the specific implementation, the computer 14 displays the temperature parameter, and when the temperature is observed to decrease by a worker, the sound pressure sensor 7 can be removed.
Step nine, unloading the casting: after the solid sample is cooled to room temperature, the ultrasonic vibration assembly 3 and the thrust rod 4 are unloaded, the casting mold 8 is unloaded, and the casting is taken out.
Example 2
As shown in fig. 3, the present embodiment is different from embodiment 1 in that the ultrasonic vibration component 3 includes a sliding guide support 3-3, an ultrasonic transducer 3-2, an amplitude transformer 3-1 and a power mechanism for driving the ultrasonic transducer 3-2 to move back and forth on the sliding guide support 3-3, the ultrasonic transducer 3-2 is connected to the sliding guide support 3-3 and can move back and forth on the sliding guide support 3-3, the ultrasonic transducer 3-2 is connected to an output end of a signal amplifier 2, the amplitude transformer 3-1 is connected to a front end of the ultrasonic transducer 3-2 and is used for pressing an outer wall of a casting mold 8, and a rear end of the ultrasonic transducer 3-2 is connected to a pressure sensor 3-4; the power mechanism comprises a screw rod connecting seat 3-10, a screw rod 3-11 connected to the screw rod connecting seat 3-10, a screw rod nut 3-12 rotatably connected to the screw rod 3-11 and a motor 3-15 for driving the screw rod 3-11 to rotate, a vertical plate 3-13 is connected to the screw rod nut 3-12, and the pressure sensor 3-4 is connected to the vertical plate 3-13; the metal solidification data acquisition and controller further comprises a pressure recorder 3-7 and a motor driver 3-14, the output end of the pressure sensor 3-4 is connected with the input end of the pressure recorder 3-7, the output end of the pressure recorder 3-7 is connected with the input end of the computer 14, the input end of the motor driver 3-14 is connected with the output end of the computer 14, and the motor 3-15 is connected with the output end of the motor driver 3-14.
When the ultrasonic vibration casting mold is specifically implemented, the amplitude transformer 3-1 is in threaded connection with the ultrasonic transducer 3-2, the computer 14 drives the motor 3-15 through the motor driver 3-14, the motor 3-15 rotates to drive the screw rod 3-11 to rotate, the screw rod nut 3-12 moves back and forth on the screw rod 3-11 to drive the pressure sensor 3-4, the ultrasonic transducer 3-2 and the amplitude transformer 3-1 to move back and forth, the extrusion force of the ultrasonic vibration component 3 on the casting mold 8 is adjusted, the extrusion force is detected by the pressure sensor 3-4, and then the extrusion force is transmitted to the computer 14 through the pressure recorder 3-7; by arranging the pressure sensors 3-4, the pressure recorder 3-7 and the motor driver 3-14, the ultrasonic vibration component 3 can be guaranteed to be pressed against the outer wall of the casting mold 8 at a certain pressure value all the time.
In the method for real-time regulation and control of wall surface resonance ultrasonic metal solidification, when the ultrasonic vibration component 3 is installed in the second step, the computer 14 drives the motors 3-13 to rotate through the motor drivers 3-14, the motors 3-13 drive the lead screws 3-11 to rotate, the lead screw nuts 3-12 move back and forth on the lead screws 3-11, so that the amplitude transformer 3-1 compresses the outer wall of the casting mold 8, and the force of the amplitude transformer 3-1 compressing the outer wall of the casting mold 8 is adjusted;
the rest of the structure and method are the same as in example 1.
In order to verify the technical effect of the real-time regulated wall surface resonance ultrasonic metal solidification device and method, COMSOL software is adopted to carry out vibration simulation, the size of the inner cavity of the casting mould is 10cm multiplied by 10cm, the wall thickness of the casting mould is 10mm, the casting mould is made of 45# steel, a variable frequency vibration test is carried out, the appearance of the vibration process is shown in figure 5A, and the test result is shown in figure 5B. Firstly, starting the resonant frequency search of the casting mould, wherein the frequency scanning range is 20kHz-40kHz, the step length is 100Hz, and obtaining the reference vibration frequency f0Is 33.1kHz (as shown in FIG. 5B). When the vibration frequency is used as a control parameter in step 802 to control, the scanning range of the vibration frequency is 31.1kHz to 35.1kHz, the step length is 10Hz, the temperature of the melt is reduced from 1233K to 933K (melting point), the optimal vibration frequency is 32.10kHz when the temperature is 1233K, the optimal vibration frequency is 32.01kHz when the temperature is 933K, as shown in fig. 5C, the frequency values in fig. 5C are counted, and the energy comparison relationship graph of the obtained frequencies is shown in fig. 5D. As can be seen from fig. 5D, if the step 802 is not executed cyclically to continuously search for the optimal vibration frequency at a temperature of 933K, the average sound energy density is as low as 78% by continuing to use the optimal vibration frequency searched for at a temperature of 1233K, and it can be seen that the step 802 is executed cyclically to continuously search for the optimal vibration frequency, which can further improve the ultrasonic effect during the melt solidification process.
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 (10)

1. The utility model provides a wall resonance supersound metal solidification equipment of real time control which characterized in that: 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 (8) poured from the top and an ultrasonic vibration assembly (3) arranged on the outer wall of the casting mold (8) in a pressing mode, and a thrust rod (4) forming counter force with the ultrasonic vibration assembly (3) to prevent the casting mold (8) from moving is further arranged on the outer wall of the casting mold (8); a melting crucible (13) for melting the solid alloy raw materials and pouring the molten alloy raw materials into the casting mold (8) is arranged above the casting mold (8);
the metal solidification data acquisition and controller comprises a sensor group, a signal acquisition circuit group, a computer (14), a variable frequency signal generator (1) and a signal amplifier (2) which are sequentially connected, wherein the sensor group comprises a vibration sensor (5) arranged on the outer wall surface of a casting mold (8), and a temperature sensor (6) and a sound pressure sensor (7) arranged in the casting mold (8), the signal acquisition circuit group comprises a vibration signal acquisition circuit (9), a temperature signal acquisition circuit (11) and a sound signal acquisition circuit (10), the vibration sensor (5) is connected with the vibration signal acquisition circuit (9), the temperature sensor (6) is connected with the temperature signal acquisition circuit (11), and the sound pressure sensor (7) is connected with the sound signal acquisition circuit (10); the ultrasonic vibration component (3) is connected with the output end of the signal amplifier (2), and the signal amplifier (2) is connected with the computer (14).
2. The real-time regulated wall surface resonance ultrasonic metal solidification device according to claim 1, characterized in that: the spatial position relation among the casting mould (8), the ultrasonic vibration component (3) and the thrust rod (4) is as follows: when the outer contour shape of the casting mould (8) is a shape with parallel planes, the number of the thrust rods (4) is one, and the thrust rods are arranged on the outer wall of the casting mould (8) on the plane opposite to the plane on which the ultrasonic vibration component (3) is arranged; when the outer contour shape of the casting mold (8) is a shape without parallel planes, the number of the thrust rods (4) is two, and the spatial position relationship between the ultrasonic vibration component (3) and the two thrust rods (4) meets the condition that any vertical plane separates the other two vertical planes at two sides of the vertical plane.
3. The real-time regulated wall surface resonance ultrasonic metal solidification device according to claim 2, characterized in that: the optimal spatial position relation among the casting mold (8), the ultrasonic vibration component (3) and the thrust rod (4) is determined by adopting a finite element simulation method, and the specific process is as follows:
step A1, respectively carrying out size and material modeling on the casting mould (8), the ultrasonic vibration component (3) and the thrust rod (4), and inputting corresponding material parameters;
step A2, selecting one of a plurality of feasible casting moulds (8), the spatial position relations of the ultrasonic vibration component (3) and the thrust rod (4), wherein the spatial position relations comprise the position and the direction of the contact point of the ultrasonic vibration component (3) and the casting mould (8) and the position and the direction of the contact point of the thrust rod (4) and the casting mould (8);
step A3, establishing a connection relation and boundary conditions among a casting mold (8), an ultrasonic vibration component (3) and a thrust rod (4), setting a friction coefficient among parts, setting the thrust rod (4) to be fixed, setting a vibration function and vibration parameters of the ultrasonic vibration component (3), and dividing grids; the vibration parameters comprise amplitude and vibration frequency;
step A4, setting the total length and the step length of time, carrying out simulation calculation on the vibration process, and checking the total vibration energy of the inner wall of the casting mold (8);
and A5, changing the position and the direction of the contact point of the ultrasonic vibration component (3) and the casting mould (8) and the position and the direction of the contact point of the thrust rod (4) and the casting mould (8) for multiple times, repeatedly executing the steps A3-A4, finding the corresponding space position relation among the casting mould (8), the ultrasonic vibration component (3) and the thrust rod (4) when the vibration total energy of the inner wall of the casting mould (8) is maximum, and determining the space position relation as the optimal space position relation among the casting mould (8), the ultrasonic vibration component (3) and the thrust rod (4).
4. The real-time regulated wall surface resonance ultrasonic metal solidification device according to claim 1, characterized in that: the melting crucible (13) is arranged right above the casting mold (8), the bottom of the melting crucible (13) is provided with an outflow hole for the melt in the melting crucible (13) to flow into the casting mold (8), and a plug rod (12) capable of plugging the outflow hole is arranged in the melting crucible (13).
5. The real-time regulated wall surface resonance ultrasonic metal solidification device according to claim 1, characterized in that: the ultrasonic vibration component (3) comprises a sliding guide support (3-3), an ultrasonic transducer (3-2), an amplitude transformer (3-1) and a cylinder (3-5) for driving the ultrasonic transducer (3-2) to move back and forth on the sliding guide support (3-3), the ultrasonic transducer (3-2) is connected on the sliding guide support (3-3) and can move back and forth on the sliding guide support (3-3), the ultrasonic transducer (3-2) is connected with the output end of a signal amplifier (2), the amplitude transformer (3-1) is connected at the front end of the ultrasonic transducer (3-2) and is used for pressing the outer wall of a casting mold (8), and the rear end of the ultrasonic transducer (3-2) is connected with a pressure sensor (3-4), the pressure sensor (3-4) is connected with a piston push rod (3-6) of the cylinder (3-5); the metal solidification data acquisition and controller further comprises a pressure recorder (3-7) and an air pressure controller (3-8), the output end of the pressure sensor (3-4) is connected with the input end of the pressure recorder (3-7), the output end of the pressure recorder (3-7) is connected with the input end of a computer (14), the input end of the air pressure controller (3-8) is connected with the output end of the computer (14), and the air cylinder (3-5) is connected with the output end of the air pressure controller (3-8).
6. The real-time regulated wall surface resonance ultrasonic metal solidification device according to claim 1, characterized in that: the ultrasonic vibration component (3) comprises a sliding guide support (3-3), an ultrasonic transducer (3-2), an amplitude transformer (3-1) and a power mechanism for driving the ultrasonic transducer (3-2) to move back and forth on the sliding guide support (3-3), the ultrasonic transducer (3-2) is connected to the sliding guide support (3-3) and can move back and forth on the sliding guide support (3-3), the ultrasonic transducer (3-2) is connected with the output end of the signal amplifier (2), the amplitude transformer (3-1) is connected to the front end of the ultrasonic transducer (3-2) and is used for pressing the outer wall of the casting mold (8), and the rear end of the ultrasonic transducer (3-2) is connected with a pressure sensor (3-4); the power mechanism comprises a screw rod connecting seat (3-10), a screw rod (3-11) connected to the screw rod connecting seat (3-10), a screw rod nut (3-12) rotatably connected to the screw rod (3-11) and a motor (3-15) for driving the screw rod (3-11) to rotate, a vertical plate (3-13) is connected to the screw rod nut (3-12), and the pressure sensor (3-4) is connected to the vertical plate (3-13); the metal solidification data acquisition and controller further comprises a pressure recorder (3-7) and a motor driver (3-14), the output end of the pressure sensor (3-4) is connected with the input end of the pressure recorder (3-7), the output end of the pressure recorder (3-7) is connected with the input end of the computer (14), the input end of the motor driver (3-14) is connected with the output end of the computer (14), and the motor (3-15) is connected with the output end of the motor driver (3-14).
7. The real-time regulated wall surface resonance ultrasonic metal solidification device according to claim 5 or 6, characterized in that: the creep temperature T of the amplitude transformer (3-1) is required to be met when the material of the amplitude transformer (3-1) is selectedrThe maximum temperature T is higher than the maximum temperature T of the outer surface of the casting mould (8) after castingw(ii) a The length L of the amplitude transformer (3-1) meets the formula under the condition of being as small as possible
Figure FDA0003000200820000041
And satisfies the formula L > kL·(Tw-ΔTi-Tc) Eta,; wherein m is a multiple coefficient, the value of m is a non-0 natural number, lambda is the ultrasonic wavelength in the amplitude transformer (3-1), and k isLIs a value safety coefficient, delta T, of the length of the amplitude transformer (3-1)iFor the transmission of temperature loss, T, between the mould (8) and the horn (3-1) headcIs the failure temperature of the vibration crystal inside the ultrasonic transducer (3-2), and eta is the temperature drop coefficient of the amplitude transformer (3-1).
8. A method for multi-directional coupled real-time regulated wall resonance ultrasonic metal solidification using the metal solidification apparatus of claim 1, comprising the steps of:
step one, alloy raw material loading: feeding multi-component alloy solid raw materials into a melting crucible (13);
step two, installing a metal solidification device body: after the thrust rod (4) is fixed, the outer wall of the casting mold (8) is abutted against the thrust rod (4), and then the ultrasonic vibration component (3) is pressed against the outer wall of the casting mold (8);
step three, installing a sensor group: arranging a sound pressure sensor (7) and a temperature sensor (6) in a casting mould (8), arranging a vibration sensor (5) on the outer wall surface of the casting mould (8), connecting the sound pressure sensor (7) with a sound signal acquisition circuit (10), connecting the temperature sensor (6) with a temperature signal acquisition circuit (11), and connecting the vibration sensor (5) with a vibration signal acquisition circuit (9);
step four, setting an initial value of a vibration parameter: setting initial values of vibration parameters of the ultrasonic vibration component (3), wherein the initial values of the vibration parameters comprise extrusion force F, amplitude and vibration frequency of the ultrasonic vibration component (3);
step five, searching the resonance frequency of the casting mould, and the concrete process is as follows:
step 501, the computer (14) sends a vibration frequency instruction to the variable frequency signal generator (1) according to the initial value of the vibration parameter, an electric signal sent by the variable frequency signal generator (1) is transmitted to the signal amplifier (2), the signal amplified by the signal amplifier (2) is output to the ultrasonic vibration component (3) to drive the ultrasonic vibration component (3), and the ultrasonic vibration component (3) starts to vibrate according to the initial value of the vibration parameter; in the vibration process of the ultrasonic vibration component (3), the vibration sensor (5) transmits the acquired vibration signals to the vibration signal acquisition circuit (9) through a cable and then to the computer (14), and the computer (14) records the vibration signals;
step 502, the computer (14) takes the vibration frequency as a regulation parameter, changes the vibration frequency parameter according to a set step length in a set vibration frequency value range, the ultrasonic vibration component (3) vibrates according to the vibration parameter after changing the vibration frequency, and the vibration signal collected by the vibration sensor (5) is changed accordingly;the computer (14) determines the vibration frequency parameter corresponding to the maximum vibration signal acquired by the vibration sensor (5) in the whole value range of the vibration frequency parameter as the reference vibration frequency f0；
Step six, smelting the master alloy: heating and melting the alloy solid raw material in the melting crucible (13), and preserving heat;
step seven, melt pouring: pouring the melt in the melting crucible (13) into a casting mold (8);
step eight, performing wall surface vibration three-dimensional ultrasonic metal solidification under the vibration frequency feedback control, wherein the concrete process is as follows:
step 801, the computer (14) adjusts the vibration frequency in the initial value of the vibration parameter to the reference vibration frequency f0Reference vibration frequency f0Sending to frequency conversion signal generator (1), the signal amplifier (2) is transmitted to the signal transmission that frequency conversion signal generator (1) sent, and the signal output after signal amplifier (2) enlargies is given ultrasonic vibration subassembly (3), drive ultrasonic vibration subassembly (3), and ultrasonic vibration subassembly (3) are according to benchmark vibration frequency f0Starting vibration; in the vibration process of the ultrasonic vibration component (3), the temperature sensor (6) transmits the acquired temperature signal to the temperature signal acquisition circuit (11) through a cable and then to the computer (14), the sound pressure sensor (7) acquires a sound pressure signal in the melt, transmits the acquired sound pressure signal to the sound signal acquisition circuit (10) through the cable and then to the computer (14), and the computer (14) records the sound pressure signal and the temperature signal;
step 802, the computer (14) takes the vibration frequency as the regulation parameter again, at f0-Δf～f0Within the value range of + delta f, changing the vibration frequency according to the set step length, vibrating the ultrasonic vibration component (3) according to the vibration parameter after changing the vibration frequency, and changing the sound pressure value detected by the sound pressure sensor (7); the computer (14) determines the vibration frequency corresponding to the maximum sound pressure value in the whole value range of the vibration frequency as the optimal vibration frequency, and f0Updating the value of (a) to the optimal vibration frequency; wherein, Δ f is the value radius of the vibration frequency;
step 803, the computer (14) repeatedly executes step 802, continuously searches for the optimal vibration frequency and enables the ultrasonic vibration component (3) to vibrate according to the optimal vibration frequency;
and step 804, when the temperature signal acquired by the temperature sensor (6) changes from a platform to a descending state along with the change of time, the alloy melt is close to complete solidification, and at the moment, the ultrasonic vibration assembly (3) is closed.
Step nine, unloading the casting: and after the solid sample is cooled to room temperature, unloading the ultrasonic vibration assembly (3) and the thrust rod (4), unloading the casting mold (8), and taking out the casting.
9. The method of claim 8, wherein: the vibration frequency value range in the step 502 is 20 kHz-100 kHz; the step size is 0.1 kHz.
10. The method of claim 8, wherein: in the fourth step, the extrusion force F is determined by adopting a vibration experiment of the ultrasonic vibration component (3), and the specific process is as follows:
step B1, installing a metal solidification device according to the method from the first step to the third step;
step B2, inquiring the yield strength of the material used by the casting mould (8) at the temperature when the melt is poured into the casting mould (8) and the yield strength of the material used by the ultrasonic vibration component (3) at the highest temperature of the outer surface of the casting mould (8) after casting in a material parameter table, and taking the smaller value of the two values as sigmas；
Step B3, determining the value range of the extrusion force F to be 10 Newton-KFσsS Newton, wherein KFS is the contact area of the ultrasonic vibration component (3) and the casting mold (8);
step B4, setting the amplitude of the ultrasonic vibration component (3) as the maximum amplitude and the vibration frequency as the resonance frequency, starting the single ultrasonic vibration component (3), sending a maximum amplitude instruction to the signal amplifier (2) by the computer (14), outputting a signal amplified by the signal amplifier (2) to the ultrasonic vibration component (3), driving the ultrasonic vibration component (3), and starting the ultrasonic vibration component (3) to vibrate; the vibration process of the ultrasonic vibration component (3) is 10 Newton-KFσs·SIn the value range of Newton, the value of extrusion force F is changed for a plurality of times, the computer (14) collects the sound pressure value detected by the sound pressure sensor (7), the sound pressure value is recorded as U, the change of the sound pressure U along with the change of the extrusion force F is recorded, and the U is set as U0[1-exp(-F/f0)]Performing curve fitting to obtain characteristic parameter f of extrusion force0(ii) a Wherein, U0Saturated sound pressure;
step B5, compare kff0And KFσsSize of S, will kff0And KFσsDetermining the smaller value of S as the optimal value of the extrusion force F; wherein k isfIs a characteristic coefficient; kFThe value safety coefficient of the extrusion force is obtained.
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