CN115138809A - Simulation control method for bucket tooth casting defects of large excavator - Google Patents
Simulation control method for bucket tooth casting defects of large excavator Download PDFInfo
- Publication number
- CN115138809A CN115138809A CN202210725726.6A CN202210725726A CN115138809A CN 115138809 A CN115138809 A CN 115138809A CN 202210725726 A CN202210725726 A CN 202210725726A CN 115138809 A CN115138809 A CN 115138809A
- Authority
- CN
- China
- Prior art keywords
- casting
- simulation
- bucket tooth
- bucket
- tooth
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/08—Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
- B22C9/082—Sprues, pouring cups
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/08—Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
- B22C9/088—Feeder heads
-
- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F30/00—Computer-aided design [CAD]
- G06F30/20—Design optimisation, verification or simulation
- G06F30/23—Design optimisation, verification or simulation using finite element methods [FEM] or finite difference methods [FDM]
-
- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F2119/00—Details relating to the type or aim of the analysis or the optimisation
- G06F2119/18—Manufacturability analysis or optimisation for manufacturability
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Physics & Mathematics (AREA)
- Theoretical Computer Science (AREA)
- Computer Hardware Design (AREA)
- Evolutionary Computation (AREA)
- Geometry (AREA)
- General Engineering & Computer Science (AREA)
- General Physics & Mathematics (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
Abstract
The invention discloses a method for simulating and controlling casting defects of bucket teeth for a large excavator, and relates to the technical field of liquid metal forming. The method comprises the following steps: presetting a process pouring system for bucket tooth casting according to the structural characteristics of the bucket tooth of the large excavator; drawing the bucket teeth and a matched pouring system by using three-dimensional modeling software, and exporting a 3D digital-analog file; casting simulation analysis software imports a 3D digital-analog file and carries out grid division; setting a module of process simulation parameters in the casting process of the simulation software; simulation operation of simulation calculation; computer simulation result feedback and criterion evaluation; improving and optimizing casting process schemes and parameters; and (5) confirming the optimal parameters. The method utilizes computer simulation software to simulate and optimize the bucket tooth casting process, and achieves the purposes of controlling casting defects, quickly reacting under various processes, shortening research and development period, reducing development cost and improving the quality of bucket tooth castings.
Description
Technical Field
The invention relates to the technical field of liquid metal forming, in particular to a method for simulating and controlling casting defects of bucket teeth for a large excavator.
Background
An excavator plays a very important role in economic construction as important construction equipment. The bucket tooth is one of main wearing parts of the excavating machine, and is directly contacted with materials such as ores, rocks, sand and soil in the using process, particularly the bucket tooth for a mining large excavator has severe working conditions, severe abrasion and extremely high requirements on abrasion resistance and impact resistance of products. The quality of bucket tooth product is deciding the life of bucket tooth, is directly influencing the work efficiency of excavator, and the casting is as the first production process of bucket tooth product, and the quality of bucket tooth foundry goods quality directly influences the effect and the bucket tooth final service life of follow-up heat treatment.
The sand casting process is easy to realize and low in cost, and is widely applied to bucket tooth casting production. The rationality and the feasibility of the design of the bucket tooth casting process scheme are verified in the traditional bucket tooth research and development process in a trial casting mode, a large amount of manpower, material resources and financial resources are wasted due to repeated modification and trial casting of the casting process scheme, the research and development efficiency is low, and resource waste is caused.
The main reason for the shrinkage cavity and shrinkage porosity defects in the casting process is that the molten metal cannot be supplemented to the final solidified part of the casting in the cooling and solidification process. The bucket tooth for the large excavator is larger in size, so that macroscopic shrinkage cavities and microscopic shrinkage porosity are easily formed at the thickest part of a casting section, the hot spot and other places, and the mechanical property of the casting is adversely affected.
Patent document CN 107891122B describes a method for controlling solidification defects in precision casting of aluminum alloy, which obtains a casting by repeatedly casting through changing casting temperature, optimizing a casting system and introducing gas into a mold in advance, and finally obtains an optimal process scheme. Repeated modification and trial casting of the casting process scheme wastes a large amount of manpower, material resources and financial resources, and the research and development efficiency is low, thereby causing resource waste.
Patent document CN 106649986B introduces a practical method for optimizing and matching casting parameters of a copper pipe horizontal continuous casting site based on a PROCAST simulation platform, which utilizes PROCAST to simulate the copper pipe horizontal continuous casting process and obtains an optimal parameter combination by simulating different production processes. The method has good reference significance for defect control and simulation of the tubular casting, but has very limited reference value for simulation and defect control of engineering machinery parts such as excavator bucket teeth.
Patent document CN 110976830B describes a method for controlling casting defects in an aluminum alloy shift hub, which uses a computer simulation to reduce casting defects in the shift hub by adjusting risers and configuring as many chills as possible. The mode of configuring the chilling block can obviously reduce the generation of casting defects, but the method causes the casting process to be more complicated, the casting period to be longer, the requirement on the operation proficiency of field workers is higher, and the method is not beneficial to large-scale production.
Disclosure of Invention
The invention aims to solve the technical problem of providing a method for simulating and controlling the casting defects of bucket teeth for a large excavator, overcoming the defects of the prior art, carrying out simulation analysis on the temperature field, the mold filling field, the solidification field, the macroscopic shrinkage cavity distribution and the microscopic shrinkage porosity distribution in the casting process by using a computer software simulation mode, and optimizing the bucket tooth casting process by changing the position and the size of a pouring gate, the shape, the size and the type of a dead head, the size and the position of a chill and the like, thereby greatly shortening the research and development period of bucket tooth products and effectively reducing the production cost.
In order to solve the technical problems, the invention provides the following technical scheme:
a simulation control method for casting defects of bucket teeth for a large excavator comprises the following steps:
(1) Casting system design
Designing a bucket tooth casting process pouring system according to the structural characteristics of the bucket tooth to be cast;
(2) 3D digital-to-analog rendering
Drawing the bucket teeth and a matched pouring system thereof by using three-dimensional modeling software, and exporting a 3D digital-analog file;
(3) Mesh partitioning
Importing the 3D digital-analog file into casting process simulation analysis software, carrying out grid division for simulating the casting process;
(4) Simulation parameter setting
After the grid division is completed, setting casting process related parameters in a simulation parameter setting module of the simulation software casting process according to actual conditions and a design scheme;
(5) Simulation of
After the relevant casting process parameters are set in the simulation module of the simulation software casting process, clicking to operate, and waiting for the computer to return a simulation result;
(6) Optimization of process scheme
Optimizing the casting process scheme, changing the casting system and simulation parameters, repeating the steps (2) - (5) on the optimized scheme to obtain a new simulation result, and performing comparative analysis;
(7) Bucket tooth casting
And (4) determining an optimal casting process scheme according to the steps (1) to (6), and then carrying out bucket tooth casting according to the optimal process scheme.
(8) Bucket tooth casting detection
And (3) detecting the defects of the bucket tooth casting product for the large excavator subjected to test casting, comparing the detected defects with a simulation result, and verifying the effectiveness of the control method.
Further, the method for simulating and controlling the casting defects of the bucket teeth for the large excavator comprises the following steps:
(1) Casting system design
Selecting a proper casting form, a proper casting speed, a proper pouring gate size, a proper chill position, a proper riser shape and size and the like according to the structural characteristics of the bucket tooth to be cast so as to complete the design of a bucket tooth casting process pouring system;
(2) 3D digital-to-analog rendering
Drawing the bucket tooth and a matched pouring system thereof by using three-dimensional modeling software such as 3DS Max, CATIA, UG, solidworks or C4D and the like, and exporting a 3D digital-analog file after drawing;
(3) Mesh partitioning
Importing the 3D digital-analog file into ProCAST casting process simulation analysis software, checking the correctness and integrity of the 3D digital-analog of the casting system, repairing the error part, and meshing the 3D digital-analog of the casting system after the repairing is finished;
(4) Simulation parameter setting
After the grid division is completed, setting pouring temperature, pouring time, sand box type, alloy type, heat exchange coefficient and the like in a simulation parameter setting module in the simulation software casting process;
(5) Simulation of
After relevant casting process parameters are set in a simulation module in the simulation software casting process, clicking to operate, and waiting for the completion of simulation results of returning a temperature field, a mold filling field, a solidification field, macroscopic shrinkage cavity distribution, microscopic shrinkage porosity distribution and the like by the computer simulation;
(6) Optimization of process scheme
Analyzing the simulation result obtained in the step (5), pertinently changing the position and size of a pouring gate, the shape, size and type of a dead head, the size and position of a chill and the like, optimizing a casting process scheme, and repeating the steps (2) to (5) on the optimized scheme;
(7) Bucket tooth casting
And (5) repeating the steps (1) to (6) until an optimal casting process scheme is obtained, and carrying out bucket tooth casting according to the optimal process scheme.
(8) Bucket tooth casting detection
And (3) carrying out magnetic powder lack detection, X-ray detection, ultrasonic detection, casting part planning and other detection on the bucket tooth casting part for the large excavator subjected to test casting, and comparing a detection result with a simulation result to verify the effectiveness of the control method.
According to the bucket tooth casting defect control method for the large excavator, the simulation result of the final casting process scheme is that the casting mold filling process is stable, the solidification process is a sequential solidification isolated liquid phase-free area, and no macroscopic shrinkage cavity exists in the casting.
Further, in the casting system in the step (1), the gate position of the casting system can be selected from the side surface, the tooth tip or the tail part of the bucket tooth.
Further, in the casting system in the step (1), the shape of the riser of the casting system may be circular or non-standard rectangular.
Further, the casting system in the step (1) selects whether to use the chilling block according to actual conditions.
Further, the size of the bucket tooth drawn in the three-dimensional modeling software in the step (2) is 1.0-2.0% larger than the actual size of the bucket tooth.
Further, the 3D digital-to-analog file in step (2) is preferably exported to stl format.
Further, in the step (3), the restored 3D models of the casting system have no overlap between surfaces, and no redundant surface exists in the model.
Further, the flask type in the step (4) includes: quartz sand, resin sand, glass sand, magnetite sand, ceramic sand and the like.
Further, the alloy types in the step (4) are classified according to alloy structures and include martensite steel, bainite steel, martensite-austenite dual-phase steel, and the like.
Further, if the filling field simulation result is not needed in the step (5), the simulation can be directly selected to start from the solidification stage, so that the computer simulation time is saved.
Further, the riser in the step (6) can be an open riser or a blind riser.
Further, the optimal process scheme in the step (7) allows the defect that the diameter of the bucket tooth is less than 2.0mm below 1.5cm under the condition of not influencing the use of the bucket tooth in part.
Further, the optimal process scheme in the step (7) allows the defect that the diameter of the bucket tooth is less than 1.0mm to exist below 2.0cm of the surface of the bucket tooth under the condition of not influencing the use of the bucket tooth in part.
Further, in the optimal process scheme in the step (7), no chilling block is used.
The bucket tooth casting for the large excavator has the characteristics of large volume, heavy mass, high requirements on mechanical properties of products and the like, and has high requirements on casting technology. A trial casting mode is adopted in the traditional bucket tooth research and development process to verify the reasonability and feasibility of the design of a bucket tooth casting process scheme, a large amount of manpower, material resources and financial resources are wasted due to repeated modification and trial casting of the casting process scheme, the research and development efficiency is low, and the development cost is high. The casting process can be simulated, analyzed and optimized by using a computer software simulation mode, and the research and development efficiency of bucket tooth products can be greatly improved.
Aiming at the defects of shrinkage cavity and shrinkage porosity generated in the casting in the bucket tooth casting process, research and development personnel generally reduce the defects in the casting by adjusting the size of a dead head and increasing chills at the wall thickness part and the hot spot part. The cold iron can effectively reduce the defects of shrinkage cavity and shrinkage porosity in the casting, but the introduction of the cold iron makes the molding process of the mold more complicated in the actual production process, the production period longer, the requirement on the quality of production workers is high, the large-scale production is not facilitated, and the economic benefit and the social benefit of the product are lower. In this regard, the inventors have found that the casting defect inside the tooth can be eliminated without using a chill by changing the position of the gate and fitting a non-standard rectangular riser system.
And developing a bucket tooth research and development task by using computer simulation software, developing trial production work according to the optimal casting process scheme obtained by simulation, performing gouging analysis on a trial casting, verifying the reliability of the simulation analysis result, establishing a bucket tooth casting defect control analysis model, and providing experimental reference for controlling the internal defects of the bucket tooth casting and even controlling the internal defects of the engineering machinery casting in future.
Compared with the prior art, the technical scheme of the invention has the following beneficial effects:
(1) The invention provides a simulation control method for casting defects of bucket teeth for a large excavator, which improves the product percent of pass, shortens the research and development period, saves manpower and material resources and reduces the development cost.
(2) The optimal casting process scheme obtained by the invention is easy to realize, simple to operate, easy to realize large-scale production and promote product popularization.
(3) The method of combining simulation and practice is adopted, the method has good ductility, and the established defect control analysis model has higher reference value for the design of various large excavator bucket tooth molds and even engineering machinery casting molds.
Drawings
FIG. 1 illustrates a bucket tooth casting defect simulation control flow chart;
FIG. 2 shows a bucket tooth casting process casting system of example 1;
FIG. 3 shows the distribution positions of macro-craters of example 1;
FIG. 4 shows a bucket tooth casting process casting system of example 2;
fig. 5 shows the distribution positions of macro-craters of example 2.
Detailed Description
In order to make the technical problems, technical solutions and advantages of the present invention more apparent, the following description is made in more detail with reference to the accompanying drawings and specific embodiments.
The invention provides a simulation control method for casting defects of bucket teeth for a large excavator, which comprises the following steps:
(1) Casting system design
Selecting a proper casting form, a proper casting speed, a proper pouring gate size, a proper chill position, a proper riser shape and size and the like according to the structural characteristics of the bucket tooth to be cast so as to complete the design of a bucket tooth casting process pouring system;
(2) 3D digital-to-analog rendering
Drawing the bucket tooth and a matched pouring system thereof by using three-dimensional modeling software such as 3DS Max, CATIA, UG, solidworks or C4D and the like, and exporting a 3D digital-analog file after drawing;
(3) Mesh partitioning
Importing the 3D digital-analog file into ProCAST casting process simulation analysis software, checking the correctness and integrity of the 3D digital-analog of the casting system, repairing the error part, and meshing the 3D digital-analog of the casting system after repairing is completed;
(4) Simulation parameter setting
After the grid division is completed, setting pouring temperature, pouring time, sand box type, alloy type, heat exchange coefficient and the like in a simulation parameter setting module in the simulation software casting process;
(5) Simulation of
After relevant casting process parameters are set in a simulation module in the simulation software casting process, clicking to operate, and waiting for the completion of simulation results of returning a temperature field, a mold filling field, a solidification field, macroscopic shrinkage cavity distribution, microscopic shrinkage porosity distribution and the like by the computer simulation;
(6) Optimization of process scheme
Analyzing the simulation result obtained in the step (5), pertinently changing the position and size of a pouring gate, the shape, size and type of a dead head, the size and position of a chill and the like, optimizing a casting process scheme, and repeating the steps (2) to (5) on the optimized scheme;
(7) Bucket tooth casting
And (5) repeating the steps (1) to (6) until an optimal casting process scheme is obtained, and carrying out bucket tooth casting according to the optimal process scheme.
(8) Bucket tooth casting detection
And (3) carrying out defect detection such as magnetic powder lack detection, X-ray detection, ultrasonic detection, casting piece gouging and the like on the bucket tooth casting piece for the large excavator for test casting, and comparing the detection result with the simulation result to verify the effectiveness of the control method.
Example 1
The casting of the embodiment is a bucket tooth for a large excavator, the traditional sand mold casting process is adopted, and the casting defect simulation control method comprises the following steps:
(1) Selecting a gravity casting mode according to the structural characteristics of the bucket tooth casting, wherein the casting time is 15s, the bucket tooth casting process casting system is shown in figure 2, the pouring gate is positioned at the front end of the bucket tooth, and the size of the pouring gate is 48 x 25mm 2 The riser adopts a spherical heat-insulating blind riser, the diameter of the riser neck is 100mm, and the diameter of the spherical riser is 180mm.
(2) Drawing the bucket teeth and a matched pouring system thereof by utilizing Solid works three-dimensional modeling software, and exporting a 3D digital-analog file in stl format after drawing.
(3) And importing the 3D digital-analog file into ProCAST casting process simulation analysis software, checking the correctness and integrity of the 3D digital-analog of the casting system, repairing the error part, and meshing the 3D digital-analog of the casting system after the repairing is finished.
(4) After the grid division is finished, in a simulation parameter setting module in the casting process of the simulation software, the pouring temperature is set to be 1580 ℃, the pouring time is set to be 15s, the sand box type is a resin sand box, the alloy type is low-carbon low-alloy, and the heat exchange coefficient is 498W/(m) 2 ·K)。
(5) After relevant parameters of the casting process are set in a simulation module of the simulation software casting process, clicking to operate, and waiting for the completion of computer simulation to obtain simulation results of the filling field, the solidification field and the macroscopic shrinkage cavity distribution. And analyzing according to the simulation result to obtain that the casting process is stable in mold filling, an isolated liquid phase region does not exist in the solidification process, and the distribution position of macro shrinkage cavities is shown in figure 3.
Example 2
The casting of the embodiment is a bucket tooth for a large excavator, the traditional sand casting process is adopted, and the steps of the casting defect simulation control method are the same as those of the embodiment 1. Compared with example 1, the difference is that the diameter of the spherical riser neck is increased to 120mm in step (1), 2 chilling blocks with the size of about 40X 20mm are added into the upper sand mold 3 The bucket tooth casting process casting system is shown in FIG. 4. And analyzing according to the simulation result to obtain that the casting process is stable in mold filling, an isolated liquid phase region does not exist in the solidification process, and no macroscopic shrinkage cavity exists in the casting, which is shown in figure 5.
Example 3
The casting of the embodiment is a bucket tooth for a large excavator, the traditional sand mold casting process is adopted, and the steps of the casting defect simulation control method are the same as those of the embodiment 1. Compared with the embodiment 1, the difference is that the spherical riser in the step (1) is changed into a round riser, and the size of the riser is R68X 188. And analyzing according to a simulation result to obtain that the mold filling is stable in the casting process, an isolated liquid phase region does not exist in the solidification process, and more macroscopic shrinkage cavities exist in the wall thickness part right below the riser.
Example 4
The casting of the embodiment is a bucket tooth for a large excavator, the traditional sand mold casting process is adopted, and the steps of the casting defect simulation control method are the same as those of the embodiment 1. Compared with the embodiment 1, the difference is that the riser in the step (1) is changed into a rectangular riser, and the size of the riser is R68X 188. And analyzing according to a simulation result to obtain that the casting process is stable in mold filling, an isolated liquid phase region does not exist in the solidification process, and macroscopic shrinkage cavities exist at the wall thickness part right below a dead head and the tail part of the bucket tooth.
Example 5
The casting of the embodiment is a bucket tooth for a large excavator, the traditional sand mold casting process is adopted, and the steps of the casting defect simulation control method are the same as those of the embodiment 1. Compared with the embodiment 4, the difference is that the position of the feed inlet in the step (1) is changed into the tail part of the casting, and the size is 55 multiplied by 30mm 2 . And analyzing according to a simulation result to obtain that the casting process is stable in mold filling, an isolated liquid phase region does not exist in the solidification process, and macroscopic shrinkage cavities only exist at the wall thickness position right below the riser.
Example 6
The casting of the embodiment is a bucket tooth for a large excavator, the traditional sand casting process is adopted, and the steps of the casting defect simulation control method are the same as those of the embodiment 1. Compared with example 5, the difference is that the size of the rectangular riser in step (1) is increased to R75X 208. And analyzing according to the simulation result to obtain that the casting process is stable in mold filling, an isolated liquid phase area is suspected to exist in the solidification process, and macroscopic shrinkage cavities exist only in the wall thickness position right below the riser.
Example 7
The casting of the embodiment is a bucket tooth for a large excavator, the traditional sand mold casting process is adopted, and the steps of the casting defect simulation control method are the same as those of the embodiment 1. Compared with example 6, the difference is that the size of the rectangular riser in the step (1) is increased to R85X 228; in step (5), the possible microscopic shrinkage porosity in the casting is simulated. And analyzing according to a simulation result to obtain that the casting process is stable in mold filling, an isolated liquid phase region does not exist in the solidification process, macroscopic shrinkage cavities do not exist in the casting, and only a few of dispersed microscopic shrinkage porosities exist.
Example 8
The casting of the embodiment is a bucket tooth for a large excavator, the traditional sand casting process is adopted, and the steps of the casting defect simulation control method are the same as those of the embodiment 1. Compared with the embodiment 7, the difference is that the feed inlet is changed into the side surface of the casting in the step (1), and the size is 48 multiplied by 28mm 2 . And analyzing according to a simulation result to obtain the phenomenon of turbulent flow in the casting process, wherein an isolated liquid phase region does not exist in the solidification process, and macroscopic shrinkage cavities do not exist in the casting.
Comparative example 1
The comparative example casting is a bucket tooth for a large excavator, the traditional sand casting process is adopted, and the steps of the casting defect simulation control method are the same as those of the embodiment 2. The difference compared to example 2 is that the size of 2 chills in step (1) was reduced to 20 × 20mm3. According to the analysis of the simulation result, the casting and mold filling process is stable, an isolated liquid phase area does not exist in the solidification process, but a small amount of macroscopic shrinkage cavities appear at the wall thickness part right below the riser due to the reduction of the volume of the chill.
Comparative example 2
The comparative example casting is a bucket tooth for a large excavator, the traditional sand casting process is adopted, and the steps of the casting defect simulation control method are the same as those of the embodiment 7. The difference compared to example 7 is that the casting time in step (1) was reduced to 12s. According to the analysis of the simulation result, the casting time is shortened, the casting speed is increased, the turbulence phenomenon exists in the casting mold filling process, an isolated liquid phase region does not exist in the solidification process, macroscopic shrinkage cavities do not exist in the casting, and the probability of occurrence of microscopic shrinkage porosity is slightly increased.
Comparative example 3
The comparative example casting is a bucket tooth for a large excavator, the traditional sand casting process is adopted, and the steps of the casting defect simulation control method are the same as those of the example 8. The difference compared with example 8 is that the size of the feed opening in step (1) is reduced to 48X 25mm. And analyzing according to a simulation result to obtain that the turbulence phenomenon in the casting process is intensified, an isolated liquid phase region does not exist in the solidification process, and macroscopic shrinkage cavities do not exist in the casting.
Through comparative analysis, the inventor finds that in the simulation result of the casting process scheme in the embodiment 7, no macroscopic shrinkage cavity defect exists in the casting, a small amount of microscopic shrinkage cavity defects are uniformly distributed, the casting and mold filling process is stable, the process parameter conditions are wide, no chill is required to be added, and the requirement on field operation is low. Example 7 was therefore identified as the best casting process solution. The bucket tooth test casting is developed according to the process scheme of the embodiment 7, the bucket tooth casting for the large excavator subjected to test casting is subjected to defect detection such as magnetic powder lack detection, X-ray detection, ultrasonic detection, casting planing and the like, the detection result is compared with the simulation result, and the detection result is consistent with the simulation result.
It is necessary to note here that the above embodiments are only a few embodiments of the present invention, and not all embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Claims (16)
1. A simulation control method for casting defects of bucket teeth for a large excavator is characterized by comprising the following steps:
(1) Modeling a casting system;
establishing a bucket tooth casting process pouring system model according to the structural characteristics of the bucket tooth to be cast;
(2) 3D digital-analog drawing;
drawing the bucket teeth and a matched pouring system thereof by using three-dimensional modeling software, and exporting a 3D digital-analog file;
(3) Grid division;
importing the 3D digital-analog file into casting process simulation analysis software for grid division for simulation of a casting process;
(4) Setting simulation parameters;
after the grid division is finished, setting casting process related parameters in the simulation parameter setting module of the simulation software casting process according to actual conditions and a design scheme;
(5) Performing analog simulation;
after casting process related parameters are set in the simulation module of the simulation software casting process, clicking to operate, and waiting for a computer to return a simulation result;
(6) Optimizing a process scheme;
optimizing the casting process scheme, changing a casting system and simulation parameters, repeating the steps (2) - (5) on the optimized scheme to obtain a new simulation result, and performing comparative analysis;
(7) Casting bucket teeth;
after the optimal casting process scheme is determined according to the steps (1) to (6), bucket tooth casting is carried out according to the optimal process scheme;
(8) Detecting a bucket tooth casting;
and (3) detecting the defects of the bucket tooth casting product for the large excavator subjected to test casting, comparing the detected defects with a simulation result, and verifying the effectiveness of the control method.
2. The method for simulating and controlling the casting defects of the bucket teeth for the large excavator in claim 1 is characterized by comprising the following steps of:
(1) And modeling the casting system.
Selecting a proper casting form, a casting speed, a pouring gate size, a chill position and a riser shape and size according to the structural characteristics of the bucket tooth to be cast, and completing modeling of a bucket tooth casting process pouring system;
(2) 3D digital-analog drawing;
drawing the bucket teeth and a matched pouring system thereof by using 3DS Max, CATIA, UG, solid works or C4D three-dimensional modeling software, and exporting a 3D digital-analog file after drawing;
(3) Grid division;
importing the 3D digital-analog file into ProCAST casting process simulation analysis software, checking the correctness and integrity of the 3D digital-analog of the casting system, repairing the error part, and meshing the 3D digital-analog of the casting system after the repairing is finished;
(4) Setting simulation parameters;
after the grid division is completed, setting pouring temperature, pouring time, sand box type, alloy type and heat exchange coefficient in a simulation parameter setting module of the simulation software casting process;
(5) Performing analog simulation;
after the relevant casting process parameters are set in the simulation module of the simulation software casting process, clicking to operate, and waiting for the completion of the simulation of the computer to return the simulation results of the temperature field, the mold filling field, the solidification field, the macro shrinkage cavity distribution and the micro shrinkage porosity distribution;
(6) Optimizing a process scheme;
analyzing the simulation result obtained in the step (5), pertinently changing the position and size of a pouring gate, the shape, size and type of a dead head and the size and position of a chill, optimizing a casting process scheme, and repeating the steps (2) to (5) on the optimized scheme;
(7) Casting bucket teeth;
and (4) carrying out bucket tooth casting according to the optimal process scheme until the optimal process scheme is obtained according to the steps (1) to (6).
(8) Detecting a bucket tooth casting;
and (3) carrying out magnetic powder lack detection, X-ray detection, ultrasonic detection and casting piece gouging defect detection on the bucket tooth casting piece for the large excavator for test casting, and comparing the detection result with the simulation result to verify the effectiveness of the control method.
3. The method for controlling the casting defects of the bucket teeth for the large excavator according to claim 1, wherein the simulation result of the final casting process scheme is that the casting mold filling process is stable, the solidification process is a sequential solidification isolated liquid phase-free region, and no macroscopic shrinkage cavity is formed in the final casting.
4. The method of claim 2, wherein the gating position of the casting system in step (1) is selected to be on the side, tip or tail of the tooth.
5. The method of claim 2, wherein in the step (1), the shape of the riser of the casting system is circular or non-standard rectangular.
6. The method of claim 2, wherein the casting system in step (1) selects whether to use chill according to actual conditions.
7. The method of claim 2, wherein the size of the tooth drawn in the three-dimensional modeling software in step (2) is 1.0-2.0% larger than the actual size of the tooth.
8. The method of claim 2, wherein the 3D digital-to-analog file in step (2) is preferably exported in stl format.
9. The method of claim 2, wherein in step (3), the 3D model of the casting system after repairing has no overlap between faces and no redundant faces.
10. The tooth casting defect control method for large excavators according to claim 2, characterized in that in step (4) the flask type includes: quartz sand, resin sand, glass sand, magnetite sand and ceramic sand.
11. The method of claim 2, wherein the alloy types in step (4) are classified according to alloy structures and include martensitic steel, bainitic steel, and martensite-austenite dual-phase steel.
12. The method of claim 2, wherein the modeling from the solidification stage is selected directly in step (5) if the fill-field modeling result is not needed.
13. The method of claim 2, wherein the risers in step (6) include open risers and blind risers.
14. The method of claim 1 wherein the optimum process recipe in step (7) allows for defects of less than 2.0mm diameter, in part, below 1.5cm of the tooth surface.
15. The method of claim 1 wherein the optimum process recipe in step (7) allows for defects of less than 1.0mm diameter to be present at less than 2.0cm of the tooth surface.
16. The method of claim 1, wherein the optimal process recipe in step (7) does not use chills.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202210725726.6A CN115138809A (en) | 2022-06-24 | 2022-06-24 | Simulation control method for bucket tooth casting defects of large excavator |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202210725726.6A CN115138809A (en) | 2022-06-24 | 2022-06-24 | Simulation control method for bucket tooth casting defects of large excavator |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN115138809A true CN115138809A (en) | 2022-10-04 |
Family
ID=83407504
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202210725726.6A Pending CN115138809A (en) | 2022-06-24 | 2022-06-24 | Simulation control method for bucket tooth casting defects of large excavator |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN115138809A (en) |
-
2022
- 2022-06-24 CN CN202210725726.6A patent/CN115138809A/en active Pending
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| EP1724716B1 (en) | Optimization process of a metal casting production process | |
| Ravi | Metal casting: computer-aided design and analysis | |
| Rao et al. | Parameters optimization of selected casting processes using teaching–learning-based optimization algorithm | |
| Gunasegaram et al. | Identification of critical factors affecting shrinkage porosity in permanent mold casting using numerical simulations based on design of experiments | |
| Khan et al. | A comparative study of simulation software for modelling metal casting processes | |
| CN105598379B (en) | A kind of Feeder Design method in thin-wall revolving body casting sand mold casting process predicted based on shrinkage defect | |
| Sata et al. | Bayesian inference-based investment-casting defect analysis system for industrial application | |
| CN104439086B (en) | The method for designing of rising head in a kind of non-axis symmetry intricate casting sand casting process | |
| Aravind et al. | Numerical and experimental approach to eliminate defects in al alloy pump-crank case processed through gravity die casting route | |
| Mohiuddin et al. | Experimental investigation to produce thin-walled sand casting using combination of casting simulation and additive manufacturing techniques | |
| CN113642855B (en) | Method for optimizing differential pressure casting quality of automobile aluminum alloy steering knuckle based on knowledge model base | |
| Kabnure et al. | Quality and yield improvement of ductile iron casting by simulation technique | |
| CN115138809A (en) | Simulation control method for bucket tooth casting defects of large excavator | |
| Ravi | Computer-aided casting design and simulation | |
| Wang et al. | Optimal riser design method based on geometric reasoning method and fruit fly optimization algorithm in CAD | |
| Tokova et al. | Construction of a Computer Technology for Information Support of Decisions in the Foundry Production Proces | |
| Rianmora et al. | A development of computer aided program for aluminium die-casting mold design | |
| Prashanth Yadav et al. | Modeling and simulation of investment casting to minimize shrinkage porosity in boom post | |
| CN107977514A (en) | A kind of method for preventing nodular iron casting slag inclusion | |
| Mathur et al. | Improvements in Productivity and Quality for Ductile Iron Flange Castings Using Simulation Technique | |
| Jovanović et al. | Model development for casting simulation of railway aluminothermic welding | |
| Madhuraj et al. | Modeling and simulation of clutch pressure plate casting using alternate materials | |
| Banerjee et al. | Analysis of Casting Defects in Investment Casting by Simulation | |
| Alrobei et al. | Investigation of Structure and Mechanical Characteristics of a High Manganese Steel via SolidCast Simulation Method. Metals 2023, 13, 572 | |
| Sagar et al. | Computer modelling, simulation of sand mold casting of tooth point for JCB excavator and verification |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PB01 | Publication | ||
| PB01 | Publication | ||
| SE01 | Entry into force of request for substantive examination | ||
| SE01 | Entry into force of request for substantive examination |