【作者】 舒晓俊；

【导师】 王智平；

【作者基本信息】 兰州理工大学 ， 材料加工工程， 2012， 硕士

【摘要】 铸造是制造业的基础，也是国民经济的基础产业，从汽车、机床、航空、航天、国防到人们的日常生活，都可看到铸造相关产品。铸造生产是个复杂的系统工程，影响铸件质量的因素有很多，生产一件优质铸件需要考虑诸多因素（包括工厂生产设备、员工素质、周围工作环境），同时查阅一定量的相关铸造手册资料并结合工作经验，制定出适合本厂生产的铸造工艺。为方便查询制定铸造工艺所需的相关资料，以快速制定合理地铸造工艺，同时降低生产成本，缩短产品生产周期，这使得计算机技术、数据库技术、CAD/CAE/CAM一体化技术，在铸造行业中的应用越来越广泛。本文分析了目前我国铸造业发展情况和未来趋势、国内铸造CAE技术公共服务平台的建设和发展、铸造相关数据库与铸造CAD/CAE/CAM技术的集成应用概况，针对我国目前和未来球墨铸铁件的应用发展趋势，结合实验室已开发的铸造CAE技术公共服务平台，建立球墨铸铁砂型铸造工艺系统，并对本课题组已开发的砂型铸造工艺数据库进行技术改进和数据库扩充。以Delphi XE2作为系统开发工具和以Microsoft SQLServer2008作为系统数据库平台，建立球墨铸铁砂型铸造工艺系统，在开发的系统中也可调用已改进的铸造工艺数据库中的相关数据。以实际生产中所需的各类参数为基础数据，通过对数据整理、分析、归类、计算，重点对球墨铸铁砂型铸造工艺系统中的浇注系统模块、冒口模块、模拟结果载入模块、球铁常见缺陷和防治模块等窗体进行设计和创建，并在窗体设计的基础上，为实现某一功能，进行相关程序代码的编写。所建立的系统中，不仅存储了一定量的经验数据，而且还具有对铸造工艺相关参数进行计算和修正的功能。以某厂生产的大型球墨铸铁底座铸件为例，运用球墨铸铁砂型铸造工艺系统和铸造工艺数据库，确定铸件铸造工艺参数。利用CATIAV5CAD模块完成建立零件三维模型，并根据已确定的铸造工艺参数对零件模型参数进行修改，建立铸件三维模型和砂芯芯盒模型。运用铸造CAE模拟软件Experto-ViewCast，模拟铸造充型和凝固过程，并参考系统中球铁常见缺陷和防治模块对模拟结果进行分析，优化完善铸造工艺。利用CATIAV5CAM模块对砂芯芯盒进行数控加工仿真，并生成NC代码，完成制定数控加工工艺。研究结果初步实现了球墨铸铁砂型铸造工艺系统、铸造工艺数据库与铸造CAD/CAE/CAM技术的集成应用。更多还原

【Abstract】 Casting is the foundation of manufacture as well as the basic industry of nationaleconomy. Casting products are common in automobile industry、machine tools、aerospaceindustry、national defense and even in people’s daily life. The production process of casting isa complex systematic engineering. There is a variety of factors including equipment、staffquality and work environment, influences the quality of casting products. In order to producehigh-quality foundry goods, workers have to consult a number of relevant materials andcombine them with work experience. Thus, the computer technique、database technology andthe integration technology of CAD/CAE/CAM which well lower production costs and shortenproduction cycle are extensively applied in casting industry.This paper analyzes the present situation and the future trend of Chinese casting industry,the development and construction of public service platforms of CAE technology in China aswell as the current application of relevant database technology and the integration technologyof CAD/CAE/CAM. Moreover, this thesis according to the developed public service platformof casting CAE technique, putting forward the sand casting process system based on thecurrent and future development tendency of nodular cast iron. The improvement andexpansion of database technology in sand casting process of our team are also being discussedin the paper. In the construction of sand casting process, the paper is based on all kinds ofparameters which obtained from the analysis calculation of data in actual production. Inaddition, DELPHI XE2is the system development kit of the system and Microsoft SQLServer2008is the platform of system database. This system emphases the design and creationof forms of gating system module, feeder head module, analog result loaded module and thefault and prevention module of cast iron. In form design, there is also the writing of relativeprogram in order to complete the whole programming of the sand casting process system. Thenew established system not only stored a certain amount of empirical data but also have thefunction to calculate and correct relevant parameters in casting technique.Take a large-scale casting base plate for example, the sand casting process system will beused to settle the technological parameters in casting. Firstly, the system build3D model ofcomponent based on CATIA V5CAD module. Then, the system modifies the modelparameters of component through the settled casting technique parameters to build the3Dmodel of casting and the core box mode of sand casting. Secondly, the system applies thecasting CAE simulation software named Experto-ViewCast to simulate the process of moldfilling and freezing based on the simulation software of CAD. Then, the fault and prevention module of cast iron analyzes the analog result through the reference system. And the analyzedresult will optimize the casting technique. Finally, the system will conduct numericalcontrol(NC) machining simulation to the core box mode of sand casting, and then NC codewill be produced. At last, the system completes NC machining process. The research resultrealized the operating system and database of sand casting process system as well as theintegrate application of CAD/CAE/CAM in casting.更多还原