【作者】 王世滨；

【导师】 盖登宇；

【作者基本信息】 哈尔滨工程大学 ， 材料加工工程， 2008， 硕士

【摘要】 随着铸造CAD/CAE实用化技术的日趋成熟,以及商业化铸造软件的逐步应用,将CAD/CAE技术应用于铸造工艺的辅助设计、铸件产品的开发和铸件质量的改进中具有非常重要的经济和学术意义。本文分析了铸造CAE数值模拟技术及其发展,研究了铸造模拟过程中流场、温度场、应力场数学模型建立的方法,方程的求解过程,以及影响流场、温度场、应力场因素等。通过综合利用铸造工艺的计算机辅助设计、计算机数值模拟技术解决了生产中几个典型铸件的缺陷问题。利用IronCAD实体设计软件对矿山机械定颚铸件、水轮机导叶铸件和水轮机转轮叶片铸件进行了三维实体建模和铸造工艺的计算机辅助设计,运用MAGMAsoft铸造数值模拟软件,对定颚铸件钢水充型过程的流场、导叶铸件凝固过程的温度场、水轮机转轮叶片铸件凝固过程的应力场进行了数值模拟分析。应用铸造CAD/CAE软件成功地对下述过程进行了计算机数值模拟及工艺优化的研究:1.对定颚铸件钢水充型过程的流场进行了数值模拟,对传统浇注系统和改进后的浇注系统分别进行了模拟分析,结果表明传统浇注系统浇注过程中容易使钢水发生紊流状充型,使铸件表面和内部产生大量的气孔。而改进后的浇注系统不仅使钢水充型平稳,而且实际生产的铸件表面和内部均没有气孔产生。2.对导叶铸件凝固过程的温度场进行了数值模拟,有效的预测了导叶铸件容易出现缩孔、缩松的位置,并针对上述铸造缺陷建立了顺序凝固时所需要的温度场,编制出合理的铸造工艺,使实际生产出来的导叶铸件无缩孔、缩松缺陷产生。3.对水轮机转轮叶片铸件进行了凝固过程的应力场数值模拟,成功地预测了凝固过程中应力场对叶片铸件变形量的影响,为叶片铸件生产过程中反变形量的施加提供了指导意见。并根据模拟结果进行了实际生产,结果表明,实际生产的叶片铸件的变形量完全在预测结果范围内。本文对定颚铸件、导叶铸件和叶片铸件制造过程的CAD/CAE研究,实现了用科技指导生产,为今后将CAD/CAE技术进一步应用到铸造生产中进行了一些有益的探索和尝试。总之,将计算机CAD/CAE技术应用在铸造工业中,可以快速、准确、低成本地研究铸造生产全过程。采用这项技术对于彻底改变铸造工艺方案制订中的经验不足,确保铸件质量、节约生产成本、提高铸造生产率乃至推动铸造技术的发展与进步都具有举足轻重的作用和意义。更多还原

【Abstract】 With casting CAD/CAE practical technology application development and the corresponding commercialized software using wider and wider, the CAD/CAE technology using to product development and quality improving has great economic and academic significance.In this paper the casting CAE technology and its development has been analysed. The mathematics model making, the solution of equations and the factors of flow field, temperature field and stress field have been studied.The defect problems of some typical castings have been solved using casting CAD/CAE. Three-dimensional modeling of Front-end casting of mining machinery, casting of Vane hydraulic-turbine and Blade casting of hydraulic-turbine runner are built using CAD software IronCAD. The flow field of Front-end casting, temperature field of Vane casting and stress field of Blade casting are simulated using casting numerical simulation software MAGMAsoft.The following cast processes was simulated and optimized using CAD/CAE software:1. Front-end casting filling course has been simulated using numerical simulation technology. The comparative study of simulation of tradition gating system and improved gating system indicate that tradition gating system has turbulent form filling in molten steel, a large number of gas cavity made in surface and inside of casting. When using improved gating system, not only molten steel fills steady but also there is no gas cavity of casting surface and inside of product.2. Temperature field of solidify process of vane casting was simulated. The location of shrinkage cavity and shrinkage porosity was predicted. The temperature field solidified in proper order was set up. The appropriate foundry technique according to it used in vane casting production and there is not shrinkage cavity and shrinkage porosity.3. The stress field simulation during solidify process of hydraulic-turbine runner blade casting was made. The deformation of casting caused by stress field was predicted. Following the result the oppose deformation allowance in the production process of the blade casting was added. According to the result of simulation the blade casting was made, which deformation totally in the range of predict.Using CAD/CAE technology studied Front-end casting, Vane casting and Blade casting making process. The results direct production successful. With science exploration and application trying for CAD/CAE and technology, it goes on some beneficial technology to cast producing in the future.CAD/CAE technology application in cast industry studies the whole course of cast production speediness, nicety and low cost. This technology changes the experimental reliance of the casting technology scheme making. It assures casting quality, saves casting cost and raises casting productivity. It can also promote cast technological progress.更多还原