铸造充型过程数值模拟技术的研究现状与展望
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摘要
通过对铸造充型过程的可视化数值模拟研究,可以有效地预测铸件产生缺陷的位置及原因,用科学的方法来指导实际生产。本文在充分了解铸造充型数值模拟相关理论的基础上,综述了充型过程数值模拟的发展过程及最新的研究成果,总结了模拟所用的主要算法、验证方法及相关模拟软件,并对铸造充型过程数值模拟技术的发展作了简单的展望。
Through the visual numerical simulation study of the casting filling process, it can effectively predict the position of the casting defects and the causes of the defect, and using scientific methods to guide the actual production can be realized. Based on the full understanding of related theories of numerical simulation of filling process, the development process and the latest research results of the numerical simulation of the filling process was summarized, the main algorithm used in the simulation, the verification method and the relevant simulation software were summarized. The development of numerical simulation of the filling process was prospected simply.
Through the visual numerical simulation study of the casting filling process, it can effectively predict the position of the casting defects and the causes of the defect, and using scientific methods to guide the actual production can be realized. Based on the full understanding of related theories of numerical simulation of filling process, the development process and the latest research results of the numerical simulation of the filling process was summarized, the main algorithm used in the simulation, the verification method and the relevant simulation software were summarized. The development of numerical simulation of the filling process was prospected simply.
引文
[1]柳百成.铸件充型凝固过程数值模拟国内外研究进展[J].铸造,1999(8):40-45.
[2]相志磊,吴丽娟,柴丽华,等. TiAl合金精密铸造计算机数值模拟的研究现状与展望[J].材料导报, 2014, 28(1):132-136.
[3]潘玉洪.熔模铸造蜡模表面欠注等缺陷分析[J].凿岩机械气动工具,2014(2):20-22.
[4]刘东戎,杨智鹏,王丽萍,等.铸造充型过程数值模拟技术的发展及现状评述[J].哈尔滨理工大学学报, 2016, 21(3):96-100.
[5]薛莉,毛红奎,徐宏,等.铸造充型过程的数值模拟研究现状及发展[J].热加工工艺,2010,39(3):80-84.
[6]齐慧.铸件流场与温度场耦合计算的数值模拟研究[D].成都:四川大学,2002.
[7]周建新,刘瑞祥,陈立亮,等.华铸CAE软件在特种铸造中的应用[J].铸造技术,2003,24(3):174-175.
[8] Pehlke R D. Computer simulation of solidification processes-the evolution of a technology[J]. Metallurgical&Materials Transactions B, 2002, 33(4):519-541.
[9]李峰.导风叶轮熔模铸造过程数值模拟与工艺优化[D].镇江:江苏大学,2013.
[10]袁浩扬.铸件形成过程传热与流动耦合数值模拟的研究[D].武汉:华中科技大学, 1995.
[11] Hwang W S, Stoehr R A. Fluid flow wodeling for computer-aided design of castings[J]. JOM, 1983, 35(10):22-29.
[12] Desai V,Berry T,Kim C. Computer simulation of forced and natural convection during filling of a casting[J].Journal of Japan Foundry Engineering Society,1984,92:519-528.
[13] Lin H J, Hwang W S. Three-dimensional fluid flow simulation for mold filling[J]. Transactions of the American Foundrymen's Society, 1989.
[14] Anzai K, Uchida T, Kataoka K. Prediction of defects in die castings by quasi three-dimensional flow analysis[J]. Journal of Japan Foundry Engineering Society, 1988, 60.
[15]刘郁丽,杨合,詹梅.摩擦对叶片精锻预成形性毛坯放置位置影响规律的研究[J].机构工程学报,2003,39(1):97-100.
[16] Sirrell B,Holliday M,Campbell J. The benchmark test 1995[C]//Proceedings of International Conference on Modeling of Casting,Welding and Advanced Solidification Process VII.London,UK,1995:915-1013.
[17] Pan S M, Ho Y H, Hwang W S. Three-dimensional fluid flow model for gas-stirred ladles[J]. Journal of Materials Engineering&Performance, 1997, 6(3):311-318.
[18] Mirbagheri S M H, Dadashzadeh M, Serajzadeh S, et al. Modeling the effect of mould wall roughness on the melt flow simulation in casting process[J]. Applied Mathematical Modelling, 2004, 28(11):933-956.
[19] Mcbride D, Humphreys N J, Croft T N, et al. Complex free surface flows in centrifugal casting:Computational modelling and validation experiments[J]. Computers&Fluids, 2013, 82(16):63-72.
[20]吴士平.铸钢件阀体铸造工艺CAD及液态金属充填铸型过程数值模拟的研究[D].合肥:中国科学技术大学,1990.
[21]孙逊,王君卿,杨恩长.液态金属充型与传热数值模拟在球铁铸造工艺设计中的应用[J].铸造,1991(12):2-5.
[22]裴清祥.铸造充型过程三维数值模拟及铸造工艺CAD系统的研究[D].北京:清华大学,1991.
[23]汪小平,吴炳尧,彭玉成.薄板压铸件充型过程流场的数值模拟[J].华南理工大学学报(自然科学版),1994(5):114-119.
[24]陈立亮,刘瑞详,林汉同,等.气化模铸造充填过程的三维数值模拟[J].铸造,1995(11):17-20.
[25]郭红星,杨志强.数值模拟技术在充型凝固过程中的应用[J].铸造技术, 2016(12):2676-2680.
[26]邱伟,高志强.用改进的SOLA—VOF法模拟铸造充型过程[J].清华大学学报(自然科学版), 1997(11):42-45.
[27]闻星火,王孝东.基于柱坐标系的充型与凝固模拟系统的开发[J].特种铸造及有色合金,1998(1):52-55.
[28]贾良荣,熊守美,冯伟明,等.压力铸造充型过程流动与传热数值模拟的研究[J].清华大学学报(自然科学版), 2001, 41(2):8-11.
[29]薛祥,张跃冰.充型过程的数值模拟及水力模拟实验验证[J].材料科学与工艺, 2002, 10(1):77-80.
[30]王罡,熊守美,都志辉,等.压铸充型过程模拟并行搜索算法[J].清华大学学报(自然科学版), 2002, 42(8):1042-1044.
[31]程万里,熊守美,柳百成.低压铸造过程充型模拟简化模型的研究[J].铸造,2003,52(8):609-612.
[32]马秋,于彦东,赵康培.镁合金压铸件充型过程的数值模拟技术研究[J].哈尔滨理工大学学报,2004,9(4):28-30.
[33]张明远,陈立亮,庞盛永,等.基于投影-水平集方法充型过程气-液两相流数值模拟[J].铸造,2010,59(5):478-481.
[34]郭永正.压蜡机充型流场的数值模拟研究[D].秦皇岛:燕山大学,2015.
[35]韩李娜. 55℃-100℃高温压蜡机蜡模充型流场可视化研究[D].秦皇岛:燕山大学, 2013.
[36]韩昌仁,周铁涛,柴增田,等.熔模精密铸造蜡模充型过程的数值模拟[J].特种铸造及有色合金,2001(3):38-39.
[37]张舒娟,侯华,杨晶,等.充型过程的数值模拟技术[J].材料导报,2007,26(3):104-107.
[38] Frisch U, Hasslacher B, Pomeau Y,等.代替Navier-Stokes方程的格子气自动机[J].力学进展,1987(1):78-82.
[39]米国发,刘翔宇,王狂飞.铸造充型过程数值模拟的研究进展及应用[J].河南理工大学学报(自然科学版), 2007, 26(3):334-339.
[40]孙逊,安阁英,苏仕方,等.铸件充型凝固过程数值模拟发展现状[J].铸造,2000(2):84-88.
[41]凌云,王红红,周建新,等.钛合金离心铸造数值模拟技术及应用[J].铸造设备与工艺,2015(1):31-34.
[42]衣春雷.熔模铸造薄壁铸件工艺优化的实验及数值模拟研究[D].青岛:青岛理工大学, 2012.
[2]相志磊,吴丽娟,柴丽华,等. TiAl合金精密铸造计算机数值模拟的研究现状与展望[J].材料导报, 2014, 28(1):132-136.
[3]潘玉洪.熔模铸造蜡模表面欠注等缺陷分析[J].凿岩机械气动工具,2014(2):20-22.
[4]刘东戎,杨智鹏,王丽萍,等.铸造充型过程数值模拟技术的发展及现状评述[J].哈尔滨理工大学学报, 2016, 21(3):96-100.
[5]薛莉,毛红奎,徐宏,等.铸造充型过程的数值模拟研究现状及发展[J].热加工工艺,2010,39(3):80-84.
[6]齐慧.铸件流场与温度场耦合计算的数值模拟研究[D].成都:四川大学,2002.
[7]周建新,刘瑞祥,陈立亮,等.华铸CAE软件在特种铸造中的应用[J].铸造技术,2003,24(3):174-175.
[8] Pehlke R D. Computer simulation of solidification processes-the evolution of a technology[J]. Metallurgical&Materials Transactions B, 2002, 33(4):519-541.
[9]李峰.导风叶轮熔模铸造过程数值模拟与工艺优化[D].镇江:江苏大学,2013.
[10]袁浩扬.铸件形成过程传热与流动耦合数值模拟的研究[D].武汉:华中科技大学, 1995.
[11] Hwang W S, Stoehr R A. Fluid flow wodeling for computer-aided design of castings[J]. JOM, 1983, 35(10):22-29.
[12] Desai V,Berry T,Kim C. Computer simulation of forced and natural convection during filling of a casting[J].Journal of Japan Foundry Engineering Society,1984,92:519-528.
[13] Lin H J, Hwang W S. Three-dimensional fluid flow simulation for mold filling[J]. Transactions of the American Foundrymen's Society, 1989.
[14] Anzai K, Uchida T, Kataoka K. Prediction of defects in die castings by quasi three-dimensional flow analysis[J]. Journal of Japan Foundry Engineering Society, 1988, 60.
[15]刘郁丽,杨合,詹梅.摩擦对叶片精锻预成形性毛坯放置位置影响规律的研究[J].机构工程学报,2003,39(1):97-100.
[16] Sirrell B,Holliday M,Campbell J. The benchmark test 1995[C]//Proceedings of International Conference on Modeling of Casting,Welding and Advanced Solidification Process VII.London,UK,1995:915-1013.
[17] Pan S M, Ho Y H, Hwang W S. Three-dimensional fluid flow model for gas-stirred ladles[J]. Journal of Materials Engineering&Performance, 1997, 6(3):311-318.
[18] Mirbagheri S M H, Dadashzadeh M, Serajzadeh S, et al. Modeling the effect of mould wall roughness on the melt flow simulation in casting process[J]. Applied Mathematical Modelling, 2004, 28(11):933-956.
[19] Mcbride D, Humphreys N J, Croft T N, et al. Complex free surface flows in centrifugal casting:Computational modelling and validation experiments[J]. Computers&Fluids, 2013, 82(16):63-72.
[20]吴士平.铸钢件阀体铸造工艺CAD及液态金属充填铸型过程数值模拟的研究[D].合肥:中国科学技术大学,1990.
[21]孙逊,王君卿,杨恩长.液态金属充型与传热数值模拟在球铁铸造工艺设计中的应用[J].铸造,1991(12):2-5.
[22]裴清祥.铸造充型过程三维数值模拟及铸造工艺CAD系统的研究[D].北京:清华大学,1991.
[23]汪小平,吴炳尧,彭玉成.薄板压铸件充型过程流场的数值模拟[J].华南理工大学学报(自然科学版),1994(5):114-119.
[24]陈立亮,刘瑞详,林汉同,等.气化模铸造充填过程的三维数值模拟[J].铸造,1995(11):17-20.
[25]郭红星,杨志强.数值模拟技术在充型凝固过程中的应用[J].铸造技术, 2016(12):2676-2680.
[26]邱伟,高志强.用改进的SOLA—VOF法模拟铸造充型过程[J].清华大学学报(自然科学版), 1997(11):42-45.
[27]闻星火,王孝东.基于柱坐标系的充型与凝固模拟系统的开发[J].特种铸造及有色合金,1998(1):52-55.
[28]贾良荣,熊守美,冯伟明,等.压力铸造充型过程流动与传热数值模拟的研究[J].清华大学学报(自然科学版), 2001, 41(2):8-11.
[29]薛祥,张跃冰.充型过程的数值模拟及水力模拟实验验证[J].材料科学与工艺, 2002, 10(1):77-80.
[30]王罡,熊守美,都志辉,等.压铸充型过程模拟并行搜索算法[J].清华大学学报(自然科学版), 2002, 42(8):1042-1044.
[31]程万里,熊守美,柳百成.低压铸造过程充型模拟简化模型的研究[J].铸造,2003,52(8):609-612.
[32]马秋,于彦东,赵康培.镁合金压铸件充型过程的数值模拟技术研究[J].哈尔滨理工大学学报,2004,9(4):28-30.
[33]张明远,陈立亮,庞盛永,等.基于投影-水平集方法充型过程气-液两相流数值模拟[J].铸造,2010,59(5):478-481.
[34]郭永正.压蜡机充型流场的数值模拟研究[D].秦皇岛:燕山大学,2015.
[35]韩李娜. 55℃-100℃高温压蜡机蜡模充型流场可视化研究[D].秦皇岛:燕山大学, 2013.
[36]韩昌仁,周铁涛,柴增田,等.熔模精密铸造蜡模充型过程的数值模拟[J].特种铸造及有色合金,2001(3):38-39.
[37]张舒娟,侯华,杨晶,等.充型过程的数值模拟技术[J].材料导报,2007,26(3):104-107.
[38] Frisch U, Hasslacher B, Pomeau Y,等.代替Navier-Stokes方程的格子气自动机[J].力学进展,1987(1):78-82.
[39]米国发,刘翔宇,王狂飞.铸造充型过程数值模拟的研究进展及应用[J].河南理工大学学报(自然科学版), 2007, 26(3):334-339.
[40]孙逊,安阁英,苏仕方,等.铸件充型凝固过程数值模拟发展现状[J].铸造,2000(2):84-88.
[41]凌云,王红红,周建新,等.钛合金离心铸造数值模拟技术及应用[J].铸造设备与工艺,2015(1):31-34.
[42]衣春雷.熔模铸造薄壁铸件工艺优化的实验及数值模拟研究[D].青岛:青岛理工大学, 2012.