镁合金挤压铸造过程数值模拟技术研究
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摘要
当前航空、航天、汽车等领域均对零部件的轻量化提出了较高的要求,镁合金作为一种良好的轻型结构材料备受关注；同时,挤压铸造过程中液体金属在压力作用下凝固,可获得组织细密、质量好、性能高、表面光洁、机加工量少的优质零件,因此,镁合金挤压铸造具有重要的发展前景。另外,成型过程数值模拟技术在优化工艺设计,缩短产品试制周期,降低生产成本,控制质量性能等方面日益成为实验技术的重要支持和补充,所以,对镁合金挤压铸造成形过程进行数值模拟具有重要意义。本论文主要研究内容如下：
(1)阐述充型过程数学模型及其有限差分离散方法,并开发基于FDM (Finite Differential Method)的镁合金挤压铸造充型过程的数值模拟程序,分析冲头运动速度对铸件质量的影响。
(2)以等效比热法为基础,并根据ADI (Alternating Direction Implicit)方法的基本思想,提出一种新的高阶紧致三维导热偏微分方程计算模型,其计算精度更高且运算速度更快。
(3)首次使用模糊数学中的海明距离对温度场数值模拟结果和实验结果的相似程度进行定量分析,较图表比较而言,是一种更加科学的考察模拟计算正确性的方法。
(4)提出一种新FDM (Finite Differential Method)/FEM (Finite ElementMethod)挤压铸造温度场计算模型并通过镁合金挤压铸造实验验证了新计算模型的正确性,解决了模拟分析中,计算过程单向,不考虑挤压压力作用下热物性参数发生变化,以及复杂铸件FEM网格剖分困难的问题。
(5)提出一种新FDM/FEM挤压铸造收缩缺陷计算模型并通过铝合金挤压铸造实验验证了新计算模型的正确性,解决了国内没有专门挤压铸造收缩缺陷计算模型的问题。由于新计算模型具有通用性设计,也适用于镁合金挤压铸造收缩缺陷的预测。
(6) VTK (Visualization Toolkit)是一个面向对象的可视化类库,具有强大的可视化功能和图形、图像处理能力。介绍了VTK技术的层次结构和显示机制,并将其应用于铸造模拟软件的开发过程中,与国内同类使用OpenGL作为开发工具的软件相比,VTK具有更加优秀的显示效果。
Higher demand for light weight of components has been proposed in aviation, aerospace, automobile and other areas. Magnesium alloy has attracted much attention as a light metal structure material. We can get high quality parts which have exquisite microstructure, good physics performance and smooth surface because the liquid metal is solidificated under pressure. The squeeze casting of magnesium alloy has the broad development prospect. With the rapid development of the computer techniques, numerical simulation technique is increasingly becoming an important support and complement to experiment techniques in optimizing the technological design, shortening the trial-production periods of the product, reducing the cost, and insuring the product quality and properties. Therefore, it is significant to simulate the filling and solidification processes of squeeze casting. The main contents are as follows.
(1) The mathematical model and finite difference method are discussed. Based on the FDM method, we develop the numerical calculation program. This program is used to calculate the filling processes of squeeze casting. The influence of different speeds of plunger on quality is analyzed.
(2) In this paper, Alternating Direction Implicit method and equivalent specific heat method are applied to establish a new high order mathematical model of3D temperature field, which could largely improve arithmetic speed and numerical precision.
(3) The fuzzy mathematical theory is introduced, and the degree of similarity between the simulation results and experimental results is analyzed quantitatively by the Hamming Distance for the first time. This method is more scientific than the figure analysis.
(4) A new FDM/FEM model has been developed to simulate the temperature field during the solidification process of squeeze casting. Squeeze casting experiments of magnesium alloy are incited for validating the new FDM/FEM model. It is shown that the results of numerical simulation are in agreement with the experimental results. Through this model, the influence of pressure on thermal physical parameters is considered, and the problem of getting the finite element meshes is resolved.
(5) In this paper, a new FDM/FEM model has been developed to simulate the shrinkage defect. Squeeze casting experiments of aluminum alloy are incited for validating the new FDM/FEM model. It is shown that the results of numerical simulation are in good agreement with the experimental results. This FDM/FEM model is also suitable to the shrinkage defect prediction of magnesium alloy.
(6) VTK is an object-oriented visualized class library. It has extensive capability in visualization and graphic processing. In this paper, the hierarchy and display way about VTK is introduced, and VTK is used in casting simulation software. Compared to other similar softwares that display results using OpenGL, the casting simulation software using VTK can display results of simulation more realistic.
(1)阐述充型过程数学模型及其有限差分离散方法,并开发基于FDM (Finite Differential Method)的镁合金挤压铸造充型过程的数值模拟程序,分析冲头运动速度对铸件质量的影响。
(2)以等效比热法为基础,并根据ADI (Alternating Direction Implicit)方法的基本思想,提出一种新的高阶紧致三维导热偏微分方程计算模型,其计算精度更高且运算速度更快。
(3)首次使用模糊数学中的海明距离对温度场数值模拟结果和实验结果的相似程度进行定量分析,较图表比较而言,是一种更加科学的考察模拟计算正确性的方法。
(4)提出一种新FDM (Finite Differential Method)/FEM (Finite ElementMethod)挤压铸造温度场计算模型并通过镁合金挤压铸造实验验证了新计算模型的正确性,解决了模拟分析中,计算过程单向,不考虑挤压压力作用下热物性参数发生变化,以及复杂铸件FEM网格剖分困难的问题。
(5)提出一种新FDM/FEM挤压铸造收缩缺陷计算模型并通过铝合金挤压铸造实验验证了新计算模型的正确性,解决了国内没有专门挤压铸造收缩缺陷计算模型的问题。由于新计算模型具有通用性设计,也适用于镁合金挤压铸造收缩缺陷的预测。
(6) VTK (Visualization Toolkit)是一个面向对象的可视化类库,具有强大的可视化功能和图形、图像处理能力。介绍了VTK技术的层次结构和显示机制,并将其应用于铸造模拟软件的开发过程中,与国内同类使用OpenGL作为开发工具的软件相比,VTK具有更加优秀的显示效果。
Higher demand for light weight of components has been proposed in aviation, aerospace, automobile and other areas. Magnesium alloy has attracted much attention as a light metal structure material. We can get high quality parts which have exquisite microstructure, good physics performance and smooth surface because the liquid metal is solidificated under pressure. The squeeze casting of magnesium alloy has the broad development prospect. With the rapid development of the computer techniques, numerical simulation technique is increasingly becoming an important support and complement to experiment techniques in optimizing the technological design, shortening the trial-production periods of the product, reducing the cost, and insuring the product quality and properties. Therefore, it is significant to simulate the filling and solidification processes of squeeze casting. The main contents are as follows.
(1) The mathematical model and finite difference method are discussed. Based on the FDM method, we develop the numerical calculation program. This program is used to calculate the filling processes of squeeze casting. The influence of different speeds of plunger on quality is analyzed.
(2) In this paper, Alternating Direction Implicit method and equivalent specific heat method are applied to establish a new high order mathematical model of3D temperature field, which could largely improve arithmetic speed and numerical precision.
(3) The fuzzy mathematical theory is introduced, and the degree of similarity between the simulation results and experimental results is analyzed quantitatively by the Hamming Distance for the first time. This method is more scientific than the figure analysis.
(4) A new FDM/FEM model has been developed to simulate the temperature field during the solidification process of squeeze casting. Squeeze casting experiments of magnesium alloy are incited for validating the new FDM/FEM model. It is shown that the results of numerical simulation are in agreement with the experimental results. Through this model, the influence of pressure on thermal physical parameters is considered, and the problem of getting the finite element meshes is resolved.
(5) In this paper, a new FDM/FEM model has been developed to simulate the shrinkage defect. Squeeze casting experiments of aluminum alloy are incited for validating the new FDM/FEM model. It is shown that the results of numerical simulation are in good agreement with the experimental results. This FDM/FEM model is also suitable to the shrinkage defect prediction of magnesium alloy.
(6) VTK is an object-oriented visualized class library. It has extensive capability in visualization and graphic processing. In this paper, the hierarchy and display way about VTK is introduced, and VTK is used in casting simulation software. Compared to other similar softwares that display results using OpenGL, the casting simulation software using VTK can display results of simulation more realistic.
引文
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