ZTA_p/HCCI复合材料凝固过程中的温度场和热应力的数值模拟
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摘要
基于有限元分析软件,模拟了在铸造过程中ZTA(Zr O2增韧Al2O3)陶瓷颗粒增强高铬铸铁基(HCCI)复合材料的温度场和热应力。在凝固初期分别以均匀初始温度和非均匀初始温度研究了铸件凝固过程的温度场。充型结束后,当把凝固的初始温度当作不稳定温度场时,更接近实际条件。在研究铸件的温度场过程中,考虑了不同蜂窝形状预制体对温度场的影响。应用了热弹塑性力学模型精确地描述了铸件热应力分布。分别研究了含有不同结构预制体的铸件的热应力,结果表明:热应力会随着预制体孔的边数的增加而逐渐减小。最后预测了热裂纹缺陷,优化了落砂工艺参数。模拟结果和实验结果高度吻合。
As advanced wear-resistant materials, it is important to promote the process and application of high chromium cast iron(HCCI) matrix composite reinforced by zirconia toughened alumina ceramic particles(ZTAp/HCCI composite). For the purpose of wider applications of this kind of composite, it is urgent to optimize the process parameters of casting process for it. Based on the finite element software the temperature field and thermal stress in ZTAp/HCCI composite during casting process were simulated. The temperature fields of castings are investigated using the uniform initial temperature and the non-uniform initial temperature at the beginning of solidification. It is more appropriate to the actual situation at the end of mold filling process when the initial temperature of solidification is considered as an unstable temperature field. The influence from performs with different honeycomb shapes is considered in the calculations of temperature fields of castings. In this work, the thermo-elastic plastic model was used to accurately describe the thermal stress in the castings with different honeycomb shapes of preforms, and the results indicate that the thermal stress in them decreases with the increase of edge number of holes in preforms. Finally, the hot crack in castings is predicted and the shakeout process is optimized. It is concluded that the simulated results are in good agreement with the experimental results.
As advanced wear-resistant materials, it is important to promote the process and application of high chromium cast iron(HCCI) matrix composite reinforced by zirconia toughened alumina ceramic particles(ZTAp/HCCI composite). For the purpose of wider applications of this kind of composite, it is urgent to optimize the process parameters of casting process for it. Based on the finite element software the temperature field and thermal stress in ZTAp/HCCI composite during casting process were simulated. The temperature fields of castings are investigated using the uniform initial temperature and the non-uniform initial temperature at the beginning of solidification. It is more appropriate to the actual situation at the end of mold filling process when the initial temperature of solidification is considered as an unstable temperature field. The influence from performs with different honeycomb shapes is considered in the calculations of temperature fields of castings. In this work, the thermo-elastic plastic model was used to accurately describe the thermal stress in the castings with different honeycomb shapes of preforms, and the results indicate that the thermal stress in them decreases with the increase of edge number of holes in preforms. Finally, the hot crack in castings is predicted and the shakeout process is optimized. It is concluded that the simulated results are in good agreement with the experimental results.
引文
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[23]Nan J P.Numerical simulation of sodium silicate sand casting process for turbine blade[D].Changsha:Central South University,2011(南江鹏.水轮机叶片的水玻璃砂型铸造过程数值模拟研究[D].长沙:中南大学,2011)
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[26]Owusu Y A.Physical-chemistry study of sodium silicate as a foundry sand binder[J].Adv.Colloid Interface Sci..,1982,18:57
[2]Zhou M J,Jiang Y H,Chong X Y.Interface transition layer interaction mechanism for ZTAP/HCCI composites[J].Sci.Eng.Compos.Mater.,2017.https://doi.org/10.1515/secm-2016-0332
[3]Zhao S M,Zhang X M,Zheng K H,et al.Fabrication of ZTA/high chromium cast iron matrix composites and its abrasive wear resistant[J].J.Foundry Technol.,2011,32:1673(赵散梅,张新明,郑开宏等.ZTA/高铬铸铁基复合材料的制备及磨损性能研究[J].铸造技术,2011,32:1673)
[4]Fu X J,Liao D M,Zhou J X,et al.Bidirectional coupled simulation for casting thermal stress based on ANSYS[J].J.Casting,2011,60:1103(傅显钧,廖敦明,周建新等.基于ANSYS的铸造过程热应力双向耦合模拟[J].铸造,2011,60:1103)
[5]Sun L Y.Numerical simulation of casting thermal stress based on ANSYS and inte CAST[D].Wuhan:Huazhong University of Science and Technology,2013(孙凌宇.基于华铸CAE/ANSYS数值模拟集成系统的铸造热应力分析[D].武汉:华中科技大学,2013)
[6]Jiao Y N,Liu B C.Simulation of metal solidification using a coupling macroscopic heat transfer and Monte Carlo method[A].The5th Asian Foundry Conference[C].Nanjing,1998,5:11
[7]Shi D L,Zhu J X.Numerical simulation of stress in quenching-cool process[J].Hot Work Technol.,2007,36:79(史东丽,朱菊香.淬火过程应力场的计算机模拟[J].热加工工艺,2007,36:79)
[8]Liu Y,Qin S W,Zuo X W,et al.Finite element simulation and experimental verification of quenching stress in fully through-hardened cylinders[J].Acta Metall.Sin.,2017,53:733(刘玉,秦盛伟,左训伟等.全淬透圆柱件淬火应力的有限元模拟及实验验证[J].金属学报,2017,53:733)
[9]Deng D A,Zhang Y B,Li S,et al.Influence of solid-state phase transformation on residual stress in P92 steel welded joint[J].Acta Metall.Sin.,2016,52:394(邓德安,张彦斌,李索等.固态相变对P92钢焊接接头残余应力的影响[J].金属学报,2016,52:394)
[10]Wang X,Hu L,Chen D X,et al.Effect of martensitic transformation on stress evolution in multi-pass butt-welded 9%Cr heat-resistant steel pipes[J].Acta Metall.Sin.,2017,53:888(王学,胡磊,陈东旭等.马氏体相变对9%Cr热强钢管道多道焊接头残余应力演化的影响[J].金属学报,2017,53:888)
[11]Li Q,Wang Z X,Xie S Y.Research on the development of mathematical model of the whole process of electroslag remelting and the process simulation[J].Acta Metall.Sin.,2017,53:494(李青,王资兴,谢树元.电渣重熔全过程的数学模型开发及过程模拟研究[J].金属学报,2017,53:494)
[12]Han S W,Shi D Q,Yang X G,et al.Computational study on microstructure-sensitive high cycle fatigue dispersivity[J].Acta Metall.Sin.,2016,52:289(韩世伟,石多奇,杨晓光等.微结构相关的高循环疲劳分散性计算方法研究[J].金属学报,2016,52:289)
[13]Giunta G,De Pietro G,Nasser H,et al.Carrera E,Petrolo M.A thermal stress finite element analysis of beam structures by hierarchical modeling[J].Composites,2016,95B:179
[14]Liu P F,Gu Z P,Yang Y H,et al.A nonlocal finite element model for progressive failure analysis of composite laminates[J].Compos.:Eng.,2016,86B:178
[15]Sun Z,Shi S S,Guo X,et al.On compressive properties of composite sandwich structures with grid reinforced honeycomb core[J].Composites,2016,94B:245
[16]Gu DD,He B B.Finite element simulation and experimental investigation of residual stresses in selective laser melted Ti–Ni shape memory alloy[J].Comp.Mater.Sci.,2016,117:22
[17]Burlayenko V N,Altenbach H,Sadowski T,et al.Computational simulations of thermal shock cracking by the virtual crack closure technique in a functionally graded plate[J].Comp.Mater.Sci.,2016,116:11
[18]Qi F G,Ding H M,Wang X L,et al.The stress and strain field distribution around the reinforced particles in Al/Ti C composites:A finite element modeling study[J].Comput.Mater.Sci.,2017,137:297
[19]Park H K,Jung J,Kim H S.Three-dimensional microstructure modeling of particulate composites using statistical synthetic structure and its thermo-mechanical finite element analysis[J].Comput.Mater.Sci.,2017,126:265
[20]Yin T T,Wang Y,He L H,et al.Stress and damage development in the carbonization process of manufacturing carbon/carbon composites[J].Comput.Mater.Sci.,2017,138:27
[21]Du J,Chong X Y,Jiang Y H,et al.Numerical simulation of mold filling process for high chromium cast iron matrix composite reinforced by ZTA ceramic particles[J].Int.J.Heat Mass Transfer,2015,89:872
[22]Zhang H S,Hu R X,Kang S T.Finite Element Analysis for ANSYS12.0 from Entry to Proficient[M].Beijing:Mechanical Industry Press,2010:10(张红松,胡仁喜,康士廷.ANSYS 12.0有限元分析从入门到精通[M].北京:机械工业出版社,2010:10)
[23]Nan J P.Numerical simulation of sodium silicate sand casting process for turbine blade[D].Changsha:Central South University,2011(南江鹏.水轮机叶片的水玻璃砂型铸造过程数值模拟研究[D].长沙:中南大学,2011)
[24]Zhao H D,Liu B C.Modeling of stable and meta-stable eutectic transformation of spheroidal graphite iron casting[J].ISIJ Int.,2001,41:986
[25]Ren F H,Dang J Z,Mao H K.ANSYS simulation of stress field during quenching process for circular shear blade of Cr Mn steel[J].Hot Work Technol.,2007,36:88(任凤华,党惊知,毛红奎.Cr Mn钢圆刀片淬火应力场ANSYS模拟[J].热加工工艺,2007,36:88)
[26]Owusu Y A.Physical-chemistry study of sodium silicate as a foundry sand binder[J].Adv.Colloid Interface Sci..,1982,18:57