目的 为探明大型复杂铝铸件铸造过程变形、开裂产生原因和影响机理,以典型应力框为研究对象,建立应力框凝固冷却过程三维仿真模型,采用凝固测温试验和基于华铸CAE的参数反求方法,获取准确的ZL114A砂型差压铸造过程热物性参数组合,并基于此,分析凝固冷却过程中应力与变形的形成规律。方法 采用ZL114A应力框差压铸造工艺试验,获得铸件典型位置凝固降温曲线;基于华铸CAE仿真软件和正交试验设计,反求获取铸件、铸型和界面换热系数等热物性参数;模拟分析应力框凝固冷却过程应力和变形的形成机理。结果 应力框1细杆等效应力沿y轴方向分布不均,粗杆等效应力沿x轴正向逐步递减;对比粗/细杆中心截面不同厚度xx方向的应力大小,可知细杆的应力最高,粗杆1/4厚的次之,粗杆中心的最小;在应力框1各个方向的位移中,x方向位移最大,主要分布于靠近横梁1的位置,z方向位移最小,其平均值不超过0.5 mm。结论 对比应力框1典型位置尺寸的试验和仿真结果可知,两者相对误差不超过10%,证实构建的铸件凝固冷却过程仿真模型可靠,为大尺寸复杂铝铸件制造过程应力变形场演化分析提供了理论技术支撑。
Abstract
To investigate the causes and effect mechanisms of deformation and cracking during the casting process of large-scale complex aluminum castings, the work aims to take a typical stress frame as the research object and establish a 3D simulation model for the solidification and cooling process of the stress frame and then accurate thermophysical parameter sets for the ZL114A sand mold counter-pressure casting process through solidification temperature measurement experiments and with a parameter inverse method based on HuaZhu CAE, thus analyzing the formation mechanisms of stress and deformation during the solidification and cooling process accordingly. Counter-pressure casting process experiments were conducted with the ZL114A stress frame to obtain solidification cooling curves at typical locations of the casting. Based on the HuaZhu CAE simulation software and orthogonal experimental design, thermophysical parameters such as the casting, mold, and interfacial heat transfer coefficients were inversely determined. The formation mechanisms of stress and deformation during the solidification and cooling process of the stress frame were simulated and analyzed. The equivalent stress in the thin rod of the Stress Frame 1 was unevenly distributed along the y-axis direction, while the equivalent stress in the thick rod gradually decreased along the positive x-axis direction. Upon comparison of the xx-direction stress magnitudes at different thicknesses of the central cross-section of the thick/thin rods, the stress was highest in the thin rod, followed by the 1/4 thickness of the thick rod, and smallest at the center of the thick rod. Among the displacements in various directions of Stress Frame 1, the x-direction displacement was the largest, mainly distributed near Beam 1, while the z-direction displacement was the smallest, with an average value not exceeding 0.5 mm. By comparing the experimental and simulation results for the dimensions at typical locations of Stress Frame 1, the relative error is found to be within 10%, confirming the reliability of the established simulation model for the casting solidification and cooling process. This provides theoretical and technical support for the analysis of stress and deformation field evolution during the manufacturing process of large-scale complex aluminum castings.
关键词
残余应力 /
ZL114A /
应力框 /
变形 /
铸造仿真
Key words
residual stress /
ZL114A /
stress frame /
deformation /
casting simulation
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