摘要
干砂消失模铸造工艺是80年代末开始投入工业应用并逐步得以发展完善
的铸造新技术。由于其诸多优点(如铸件尺寸精度高、表面粗糙度低、机械加
工量少、环境污染小等)，该技术被认为是一项很有发展前景的近净型加工技
术和清洁生产技术。近年来，消失模铸造过程计算机模拟仿真使得如今消
失模铸造技术的自动化程度更高，优化工艺设计，缩短产品试制周期，
降低成本，减少铸件缺陷，确保铸件质量。因此，已成为铸造领域
最热门的研究课题之一。该课题就是为工艺设计提供模拟和校核手
段，以传热理论、流体力学及金属凝固理论等为基础，利用数值分
析技术、数据库技术和可视化技术等对铸造过程进行仿真，从而模
拟出在铸件充型、凝固和冷却中的流场和温度场，并根据这些物理
场对铸件质量进行预报，从而提高铸件工艺设计的准确性、高效性。
采用了PRO／E作为三维造型软件，用美国UFC公司著名的ProCAST
软件作为铸造过程计算机模拟仿真工具，深入探讨了消失模铸造过
程中的特点。在对铸造过程流场、温度场、气隙压力以及铸造缺陷
预计的数学模型进行深入分析研究的基础上，成功地制定出了一套
铸造工艺CAD／CAE的工艺流程。该课题以减速器下箱体铸件为实
例，进行了工艺CAD建模；通过对实际铸件生产条件的测定，建立
了泡沫塑料、铸件、型砂的材料参数库；合理地选择数学模型、设
置运行参数；成功地对铸件成型过程进行了模拟，细致分析比较了
两种浇注系统的优劣，并与实际相结合优化工艺参数设计。
The computer simulation for casting process is not only the cutting edge for the subject of casting technology development and the only way for improving traditional casting, but also the hot topics to all the expert in the world.
Numerical simulation for casting process may optimize craft design, shorting trial cycle, cut the cost, decrease casting defect and assure the casting quality. Because of these advantages, it has been one of the hottest topic in the foundry world. Based on the theory of heat transfer, hydrodynamics and the theory of metal solidification, by using numerical analysis technology, database technology and visual technology, this paper provided a simulation and check method for the process design to simulate the fluent field and temperature field of the filling solidification and cooling, and can predict the casting quality according to these fields, thus, by this way, improved the quality of casting draft design. Adopting Pro/E 3D software and using the famous ProCAST software of American UFC company as simulation tool in the casting process, the interfaces has been deeply researched between the two software. By our research on the fluent field, temperature field and the prediction on the casting defect, we devel
op a new technical process for casting CAD/CAM.
This paper example the casting gear box of the casting of mechanical department in the metal company and set a CAD model. By measuring actual working condition, we set up a material database for casting and sand mold, through choose reasonable model and parameters, we simulating the casting process successfully. The result of simulation is basically accord with the actual defect.
引文
[1] X. Liu, C. W. Ramsay, D. R. Askeland. Study on mold filling control mechanisms in the EPC process [J]. AFS Trans, 1994, 148: 903-914．
[2] M. Hill, A. E. Vrieze, T. L. Moody, et al. Effect of metal velocity on defect formation in AL LFCs [J]. AFS Trans, 1998, 114: 356-374．
[3] E. N. Pan, K. Y. Liao. Study on flowabilily of EPCA 356 AL alloy [J]. AFS Trans, 1998, 65: 233-242．
[4] C.-H. E. Tseng, D. R. Askeland. Study of the EPC mold filling process using metal velocity and mass and energy balances AFS Trans, 1992, 111: 519-527．
[5] Z. Liu, J. Hu, W. Ding, et al. Effect of processing parameters on mold filling in magnesium alloy EPC process [J]. AFS Trans, 2001, 014: 1425-1438．
[6] S. Shivkumar, X. Yao, M. .Makhlouf. Polymer-Melt interactions during casting formation in the lost foam process [J]. Scripta Metallurgies et Materialia 1995(1) : 39-46．
[7] 毛高波，饶群章等．负压消失模铸造铸铁合金液充填性能及影响[J]．特种铸造及有色合金，1997 (2) ：31-35．
[8] J. Fu, H. L. Tsai, D. R. Askeland. Mold filling in thin-section castings produced by EPC process [J]. AFS Trans, 1995, 103: 817-828．
[9] 傅其葛，喻德顺．真空实型铸造[M]．北京：新时代出版社，1991
[10] C.-H. E. Tseng, D. R. Askeland. A study of selected process parameters for the evaporative pattern casting process AFS Trans, 1991, 134: 455-464．
[11] 袁中岳，张中明，林尤栋．直浇道高度和浇注温度对ZL102合金消失模铸造充型能力的影响[J]．铸 造技术，1999(5) ：19-21．
[12] 魏尊杰，安阁英．消失模铸造充型过程特点研究现状[J]．铸造，1997(11) ：51-55．
[13] M. W. Hill, M. Lawrence, C. W. Ramsay, et al. Influence of Gating and other processing parameter on mold filling in the LFC process [J]. AFS Trans, 1997, 140: 443-450．
[14] C. Wang, C. W. Ramsay, D. R. Askeland. Effect of processing parameters on mold filling for gray iron EPC casting using statistical experimental techniques [ J]. AFS Trans, 1994, 151: 921-930．
[15] Y. Sun, H. L. Tsai, D. R. Askeland. Influence of pattern geometry and other process parameters on the mold filling in aluminum EPC process [J]. AFS Trans, 1995, 103: 651-662．
[16] C. Wang, C. W. Ramsay, D. R. Askeland Processing variable significance on filling thin plates in the LFC process-the staggered, nested factorial experiment [J]. AFS Trans, 1997, 138: 427-434．
[17] 刑涛 凝固过程数值模拟 电子工业出版社
[18] Upadhya G. Comprehensive Casting Analysis Model Using a Geometry-Based Technique Flowed by Fully Coupled , 3-D Fluid Flow , Heat Transfer and Solidification Kinetics Calculation . AFS Transactions, 1992:925-933
[19] X. Liu, C. W. Ramsay, D. R. Askeland. Study on mold filling control mechanisms in the EPC process [J]. AFS Trans, 1994, 148: 903-914．
[20] S. Shivkumar, X. Yao, M.Makhlouf. Polymer-Melt interactions during casting formation in the lost foam process [J]. Scripta Metallurgica et Materialia 1995(1) : 39-46．
[21] C. Wang, C. W. Ramsay, D. R. Askeland Effect of processing parameters on mold filling for
gray iron EPC casting using statistical experimental techniques [J]. AFS Trans, 1994, 151: 921-930．
[22] 马幼平，许云华等． 负压实型铸造及铸件质量[M]．北京：冶金工业出版社， 2002，5：50-58．
[23] 毛高波，饶群章等．负压消失模铸造铸铁合金液充填性能及影响[J]．特种铸造及有色合金，1997 (2) ：31-35．
[24] J. Liu, Ramsay C. W, D. R. Askeland. Effects of foam density and density gradients on metal fill in the LFC process [J]. AFS Trans, 1997, 139: 435-442．
[25] M. W. Hill, M. Lawrence, C. W. Ramsay, et al. Influence of Gating and other processing parameter on mold filling in the LFC process [J]. AFS Trans, 1997, 140: 443-450
[26] C. Wang, C. W. Ramsay, D. R. Askeland Processing variable significance on filling thin plates in the LFC process-the staggered, nested factorial experiment [J]. AFS Trans, 1997, 138: 427-434．
[27] 吴国华，罗吉荣． 消失模铸造铝液充型速度研究[J]． 特种铸造及有色合金， 2000(1) ：26-27．
[28] M. H. Warner, B. A. Miller, H. E. Littleton Pattern pyrolysis defect reduction in lost foam casting [J]. AFS Trans, 1998, 106: 777-758．
[29] J. Yang, T. Huang, J. Fu Study of gas pressure in EPC(LFC) molds [J]. AFS Trans, 1998, 126: 21-26．
[30] 吴志超，黄乃瑜，罗吉荣．干砂消失模铸造铁液流动前沿气隙的研究[J]．铸造技术，2001(1) ： 49-51．
[31] 李锋军，林青松，张殿得，等．铸铁件消失模充型速度的测试及计算[J]．现代铸铁，2002(1) ： 21-24．
[32] 傅其葛，喻德顺．真空实型铸造[M]．北京：新时代出版社，1991
[33] Z. Liu, J. Hu, W. Ding, etal. Effect of processing parameters on mold filling in magnesium alloy EPC process [J]. AFS Trans, 2001, 014: 1425-1438．
[34] 吴志超，姜道御，黄乃瑜．铸铁件EPC-V法工艺因素对充型速度的影响[J]． 特种铸造及有色 合金， 1997(6) ：5-7．
[35] M. D. Lawence, C.W.Ramsay,. D. R. Askeland. Some observations and principles for gating of lost foam castings [J]. AFS Trans, 1998, 106: 349-356．
[36] S. Shivkumar, B. Gallois. Physico-Chemical aspets of the full mold casting of aluminum alloys Part Ⅱ metal flow in simple patterns [J]. AFSTrans, 1987, 185: 805-811．
[37] 董湘怀 材料成形计算机模拟 机械工业出版社
[38] S．V．Patankar著．传热与流体流动的数值计算．第一版．北京：科学技术出版社，1983
[39] T. Hayase,J. A. C. Humphrey and R. Greif. A Consistently Formulated QUICK Scheme for Fast and Stable Convergence Using Finite-Volume Iterative Calculation Process. Journal of Computational Physics 98,1992:108-118
[40] K. Anzai, E. Niyama. A Casting CAE System with Flow and Solidification Simulation. Proceedings of Modeling of Casting and Solidification Processes, 1995
[41] X. Xue, S. F. Hansen, P. N. Hansen. Numerical Simulation and Experimental of Mold Filling Process through Depressurized and Less-Depressurized Gating System. AFS Transactions,1993(101) : 549-558
[42] E.Niyama, K.Anzai.Mold Filling Analysis Using a New VOF_Based Free Surface Tracing Algorithm, Proceeding of Molding of Casting and Solidification Process, 1995
[43] JidongZhu, Itsuo Ohnaka, Treatment of Free Surface Boundary Condition for the Solidification of Mold Filling, Proceeding of Molding of Casting and Solidification Process, 1995
[44] 孙海成．流体质量扩散的格子Boltzmann方法．力学学报，1998，30(1)
[45] 铸造全过程仿真软件ProCAST．软件世界．
[46] ProCAST User's Manual
[47] 周业明等．有限元模拟预测铸钢件的宏观缩孔缺陷．铸造．2001(12)
[48] 林清安编著．Pro／ENGINEER 2000i模具设计，北京大学出版社
[49] 黄圣杰，张盖三，洪立群编著．Pro／ENGINEER 2001高级开发实例．北京：电子工业出版社，2002． 2
[50] 曾健，王家弟等．UGⅡ和ProCAST之间的图形数据交换研究．铸造，1999(12)
[51] 白文弟．Pro／E与ProCAST接口方式的探讨．中国铸造装备与技术．2002(1) ：23-26
[52] 柳百成，荆涛编著．铸造工程的模拟仿真与质量控制．北京：机械工业出版社，2001
[53] X. Liu, C. W. Ramsay, D. R. Askeland. Study on mold filling control mechanisms in the EPC process. AFS Trans., 1994, 148: 903-914
[54] E. N. Pan, G. L. Sheu. Mold Filling Behavior in Vertical Gating Lost Foam Aluminum Alloy. AFS Trans., 2000, 01: 79-86．
[55] 傅其葛，喻德顺．真空实型铸造．北京：新时代出版社，1991．
[56] 黄乃瑜 叶升平 樊自田 消失模铸造原理及质量控制 华中科技大学出版社
[57] 消失模铸造充型过程的计算机数值模拟 矿山机械 2002 07
[58] 魏尊杰 安阁英 消失模样性能对铝合金液充型速度及间隙压力影响的数值计算
[59] 刘子利 消失模铸造充型过程的研究进展及展望 铸造 2000 04