铝合金副车架的铸造缺陷与应力模拟分析
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摘要
利用ADSTEFAN铸造模拟分析软件对副车架铸铝件铸造过程进行数值模拟,并对铸造缺陷和应力进行分析。结果发现:铸件内部存在较为严重的缩松缩孔,但铸件表面残余应力较小。采用X射线无损探伤和应力测定仪对实际铸件进行测定,验证了模拟结果中缩松缩孔的大小、位置以及残余应力值。说明了数值模拟方法的可行性,不仅为实际生产降低了成本,提高了效率,且为今后更深入的研究数值模拟在实际生产中的应用打下了基础。
Numerical simulation of casting process of cast aluminum subframe was carried out by ADSTEFAN casting simulation software. The casting defects and stress conditions were observed.It was found that the serious shrinkage and shrinkage porosity occurred inside the casting,while the surface residual stress of casting was small. The size and location of shrinkage and porosity and the residual stress value of the actual casting were tested by X-ray nondestructive testing and X-ray stress tester,the obtained results verified the applicability of the numerical simulation method. The numerical simulation method not only reduced the cost and improved the efficiency for the actual production,but also laid the foundation for the further application of the numerical simulation in the actual production.
Numerical simulation of casting process of cast aluminum subframe was carried out by ADSTEFAN casting simulation software. The casting defects and stress conditions were observed.It was found that the serious shrinkage and shrinkage porosity occurred inside the casting,while the surface residual stress of casting was small. The size and location of shrinkage and porosity and the residual stress value of the actual casting were tested by X-ray nondestructive testing and X-ray stress tester,the obtained results verified the applicability of the numerical simulation method. The numerical simulation method not only reduced the cost and improved the efficiency for the actual production,but also laid the foundation for the further application of the numerical simulation in the actual production.
引文
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[2]肖永清.铝合金是现代汽车轻量化的首选材料[J].铝加工,2005(5):36-39.
[3]王祝堂,张新华.汽车用铝合金[J].轻合金加工技术,2011,39(2):1-14.
[4]梁正伟,王权.论钢轨残余应力的测定方法[J].包钢科技,2002,28(5):8-11.
[5] LI B Q,RUAN Y M. Integrated finite element model for transient fluid flow and thermal stresses during continuous casting[J]. Journal of Thermal Stresses,1995,18(3):359-381.
[6] CHOI B H,NAM J H,LEE S W,et al. Numerical and experimental study on thermal stress in grey iron castings[J].Cast Metals,2007,20(2):58-63.
[7] HATTEL J H,HANSEN P N. A control volume based finite difference method for solving equilibrium equations in terms of displacement[J]. Applied Mathematical Modelling,1995,19(4):210-243.
[8]李世芸,李世萍.铸件在凝固过程中瞬态温度场和热应力场分析[J].昆明理工大学学报,2000,25(1):47-50.
[9]孙丽文.铸钢件三维热应力场数值模拟技术研究[D].太原:中北大学,2007.