蜂窝结构的超声波振动网络构建与应用
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摘要
选择结构合理的多振动源超声波辅助铸造网络,提高超声波辅助铸造系统的工作效率和铝合金的铸造质量,解决了传统结构超声波辅助铸造系统功率超声波分布不均匀、作用面积和作用体积小、频率谱效率和功率谱效率低、辅助铸造质量差等问题。设计的蜂窝结构超声波辅助铸造网络可以根据振动源节点的层数确定节点的个数,根据铸锭尺寸确定正六边形蜂窝单元的边长,并且实时调整超声波网络的输出功率和谐振频率。选择7节点的蜂窝结构超声波网络和4节点的传统结构超声波网络,分别应用到Φ630 mm的7085铝合金铸锭辅助铸造实验与仿真过程中。与4节点传统超声波网络相比,7节点蜂窝结构超声波网络的有效面积、有效体积、频率谱效率和平均覆盖概率分别增加了22.73%、32.81%、18.71%和0.315,平均功率谱效率与理想值的差值仅为0.27 W/cm~2,平均晶粒尺寸减小了35.82μm,说明蜂窝结构超声波辅助铸造网络的工作效率和铝合金铸造质量均有提升。
A reasonable ultrasonic vibration network was designed to improve the working efficiency and casting quality of the ultrasonic-assisted casting system, hence the problems such as small working area and volume of the ultrasonic vibration network, low efficiency of frequency spectrum and power spectrum, and poor quality of casting were solved. The designed vibration network with honeycomb structure can determine the number of nodes according to the layers of the vibration network and the side length of the hexagonal honeycomb units according to the casting ingot size, and adjust the output power and resonant frequency of the vibration network in real time. Seven-node ultrasonic vibration network with honeycomb structure and four-node ultrasonic vibration network with traditional structure were selected and applied in the experiments and simulation of casting of Φ630 mm 7085 aluminum alloy ingot. Compared with the traditional four-node ultrasonic vibration network, the effective area and volume, frequency spectrum efficiency, and average coverage probability of the seven-node honeycomb vibration network were increased by 22.73%, 32.81%, 18.71% and 0.315, respectively. The difference between the average efficiency of power spectrum and the desired value was only 0.27 W/cm~2, and the average grain size of casting is decreased by 35.82 microns. The results show that the efficiency of the ultrasonic vibration network and the quality of vibration-assisted casting are improved.
A reasonable ultrasonic vibration network was designed to improve the working efficiency and casting quality of the ultrasonic-assisted casting system, hence the problems such as small working area and volume of the ultrasonic vibration network, low efficiency of frequency spectrum and power spectrum, and poor quality of casting were solved. The designed vibration network with honeycomb structure can determine the number of nodes according to the layers of the vibration network and the side length of the hexagonal honeycomb units according to the casting ingot size, and adjust the output power and resonant frequency of the vibration network in real time. Seven-node ultrasonic vibration network with honeycomb structure and four-node ultrasonic vibration network with traditional structure were selected and applied in the experiments and simulation of casting of Φ630 mm 7085 aluminum alloy ingot. Compared with the traditional four-node ultrasonic vibration network, the effective area and volume, frequency spectrum efficiency, and average coverage probability of the seven-node honeycomb vibration network were increased by 22.73%, 32.81%, 18.71% and 0.315, respectively. The difference between the average efficiency of power spectrum and the desired value was only 0.27 W/cm~2, and the average grain size of casting is decreased by 35.82 microns. The results show that the efficiency of the ultrasonic vibration network and the quality of vibration-assisted casting are improved.
引文
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[9] VISHWANATHA H M, ERAVELLY J, KUMAR C S, et al Microstructure and mechanical properties of aluminum-alumina bulk nanocomposite produced by a novel two-step ultrasonic casting technique [J]. Metallurgical and Materials Transactions: A, 2016, 47(11): 5630-5640.
[10] 杜飞, 洪军, 李宝童, 等. 结合面参数的超声检测方法研究 [J]. 西安交通大学学报, 2013, 47(3): 19-23. DU Fei, HONG Jun, LI Baotong, et al. Contact parameter estimation with ultrasonic method [J]. Journal of Xi’an Jiaotong University, 2013, 47(3): 19-23.
[11] STCINWOLF A. Shaker random testing with low kurtosis: review of methods and application for sigma limiting [J]. Shock and Vibration, 2010, 17: 219-231.
[12] WU Shusen, ZHONG Gu, WAN Li, et al. Microstructure and properties of rheo-diecast Al-20Si-2Cu-1Ni-0.4Mg alloy with direct ultrasonic vibration process [J]. Transactions of Nonferrous Metals Society of China, 2010, 20(S3): 763-767.
[13] TONG Wen, LI Wei, XIA Chen. Effects of ultrasonic vibration on plastic deformation of AZ31 during the tensile process [J]. International Journal of Minerals Metallurgy & Materials, 2011, 18(1): 70-76.
[14] ANDREAS N, ANDREAS S. Surface properties in ultrasonic vibration assisted turning of particle reinforced aluminum matrix composites [J]. Procedia CIRP, 2014, 13: 125-130.
[15] LAI Jianping, JIANG Rongpiao, LIU Huashan, et al. Influence of cerium on microstructures and mechanical properties of AI-Zn-Mg-Cu alloys [J]. Journal of Central South University, 2012, 19(4): 869-874.
[16] ZHANG Lihua, YU Jun, ZHANG Xiaoming. Effect of ultrasonic power and casting speed on solidification structure of 7050 aluminum alloy ingot in ultrasonic field [J]. Journal of Central South University of Technology, 2010, 17(3): 431-436.
[2] 李晓谦, 李开晔, 陈铭. 超声振动对7050铝合金熔体冷却时间及凝固组织的影响 [J]. 粉末冶金材料科学与工程, 2011, 16(2): 249-254. LI Xiaoqian, LI Kaiye, CHEN Ming. Effect of ultrasonic vibration on cooling time and solidification structure of 7050 aluminum alloy melt [J]. Materials Science and Engineering of Powder Metallurgy, 2011, 16(2): 249-254.
[3] 崔莹, 李晓谦. 超声对7050铝合金显微组织及溶质固溶度的影响 [J]. 中南大学学报(自然科学版), 2012, 43(9): 3420-3425. CUI Ying, LI Xiaoqian. Effects of ultrasonic on micro-structures and solid solubility of main solute elements in aluminum alloy 7050 [J]. Journal of Central South University(Science and Technology), 2012, 43(9): 3420-3425.
[4] 陈强, 李伟华, 吴婷, 等. 数值积分函数对超声波流量计精度的影响 [J]. 西安交通大学学报, 2012, 46(9): 21-29. CHEN Qiang, LI Weihua, WU Ting, et al. Influence of numerical integration on error of ultrasonic flow meter [J]. Journal of Xi’an Jiaotong University, 2012, 46(9): 21-25.
[5] 严鲁涛, 杨志鹏, 高飞, 等. 振动试验中削波信号功率谱密度补偿 [J]. 振动、测试与诊断, 2015, 35(4): 690-696. YAN Lutao, YANG Zhipeng, GAO Fei, et al. Power spectral density compensation algorithm for signal clipping in vibration test [J]. Journal of Vibration, Measurement & Diagnosis, 2015, 35(4): 690-696.
[6] 钟建华, 齐乐华, 李妙玲, 等. 利用人工神经网络的偏光下热解炭织构类型识别 [J]. 西安交通大学学报, 2010, 44(7): 46-49. ZHONG Jianhua, QI Lehua, LI Miaoling, et al. Automatic classification of pyrocarbon texture under polarized light microscope based on artificial neural network [J]. Journal of Xi’an Jiaotong University, 2010, 44(7): 46-49.
[7] 黄凯. 基于神经网络的动态匹配超声波铸造电源的研究 [D]. 长沙: 中南大学, 2011: 45-51.
[8] 陈锡文. 基于神经网络的电力负荷预测方法研究及软件开发 [D]. 长沙: 中南大学, 2009: 19-35.
[9] VISHWANATHA H M, ERAVELLY J, KUMAR C S, et al Microstructure and mechanical properties of aluminum-alumina bulk nanocomposite produced by a novel two-step ultrasonic casting technique [J]. Metallurgical and Materials Transactions: A, 2016, 47(11): 5630-5640.
[10] 杜飞, 洪军, 李宝童, 等. 结合面参数的超声检测方法研究 [J]. 西安交通大学学报, 2013, 47(3): 19-23. DU Fei, HONG Jun, LI Baotong, et al. Contact parameter estimation with ultrasonic method [J]. Journal of Xi’an Jiaotong University, 2013, 47(3): 19-23.
[11] STCINWOLF A. Shaker random testing with low kurtosis: review of methods and application for sigma limiting [J]. Shock and Vibration, 2010, 17: 219-231.
[12] WU Shusen, ZHONG Gu, WAN Li, et al. Microstructure and properties of rheo-diecast Al-20Si-2Cu-1Ni-0.4Mg alloy with direct ultrasonic vibration process [J]. Transactions of Nonferrous Metals Society of China, 2010, 20(S3): 763-767.
[13] TONG Wen, LI Wei, XIA Chen. Effects of ultrasonic vibration on plastic deformation of AZ31 during the tensile process [J]. International Journal of Minerals Metallurgy & Materials, 2011, 18(1): 70-76.
[14] ANDREAS N, ANDREAS S. Surface properties in ultrasonic vibration assisted turning of particle reinforced aluminum matrix composites [J]. Procedia CIRP, 2014, 13: 125-130.
[15] LAI Jianping, JIANG Rongpiao, LIU Huashan, et al. Influence of cerium on microstructures and mechanical properties of AI-Zn-Mg-Cu alloys [J]. Journal of Central South University, 2012, 19(4): 869-874.
[16] ZHANG Lihua, YU Jun, ZHANG Xiaoming. Effect of ultrasonic power and casting speed on solidification structure of 7050 aluminum alloy ingot in ultrasonic field [J]. Journal of Central South University of Technology, 2010, 17(3): 431-436.