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.
Key words
residual stress /
ZL114A /
stress frame /
deformation /
casting simulation
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