机车摇枕铸件工艺的数值模拟
摘要
摇枕作为火车中的重要零部件,重载和高速对摇枕的质量提出了较高的要求。从报道和生产情况看来,摇枕所存在的问题是存在缩孔、裂纹等铸造缺陷。缺陷位置分散且不好掌握,针对以上问题,决定对摇枕的工艺设计过程采用数值模拟技术。本文已摇枕为研究对象,采用PROCAST软件进行工艺的模拟分析,并确定铸造工艺。
本文在简要阐述铸造数值模拟技术基本原理基础上,介绍了PROCAST软件所采用的有限元方法建立的温度场、流场以及应力场的数学、物理模型和进行有限元离散求解,以及铸造缺陷的判定。
对PROCAST的使用者来说,复杂零件的网格划分是比较困难的事情,本文研究了CAD软件和前处理软件与PROCAST之间的接口问题。对比发现,用pro/e生成的面网格与PROCAST有较好的兼容性,对于复杂零件能较好的解决铸型与铸件、冷铁与铸件的网格一致性的问题。
热物性参数对模拟的准确性起到相当重要的作用,本文通过PROCAST软件自带的计算系统,通过必要的修正计算出B级钢的热物性参数,并通过查找数据得到B级钢的高温性能,同时与实验得出的C级钢数据比较,验证数据的可靠性。
本文利用PROCAST的基本模块,对摇枕流动场和温度场进行了模拟,讨论了速度、温度对摇枕缺陷的影响,阐明冷铁及冒口的布置对缺陷的影响最大,通过多次模拟确定比较合理的冷铁及冒口的分布。用Anycasting软件对结果进行了对比,发现两种软件得到的结果有较好的一致性。
裂纹作为摇枕缺陷之一,对摇枕的质量有重要影响,本文阐述了热裂产生的原因,并利用PROCAST的应力模块对摇枕进行了热裂倾向、热应力大小及分布进行了模拟,通过设置合理的冷铁,有效的降低了热应力。
通过数值模拟,确定了比较合理的铸造工艺,对这种复杂的零件的生产提供了指导意义,同时也缩短了工艺准备的周期,降低了试制成本,是得到合格铸件的有力保证。
Bolster as a key part in the Locomotive,in order to meet the heavy-duty and high-speed operating environment, we need high quality of bolster. From the production and reports, we know that the bolster main problems are shrinkage、cracks and other casting defects. Defects scattered in the bolster and could not be controlled. In light of these, we decided to design process of bolster by using numerical simulation techniques. This article is to analyze and simulate the casting process of bolster by using PROCAST software,then fix the casting process.
On the basis of the theory–numerical simulation technology for casting process, this article expounds how the PROCAST to detect temperature, fluid and stress field by mathematics and physics model through finite element method (FEM) so as to figure out casting defects.
To the users of PROCAST,it is difficult to mesh the complex parts. In this paper,we discussed the interface between the CAD software and pre-processing software with PROCAST. Finally we found that the surface mesh generated by pro/e have a better compatibility to PROCAST,we can got a good match between casting and mould、casting and chill for complex parts.
Thermophysical properties played an important role to the accurate simulation. We calculated the thermal parameters of B-grade steel by using the computing system which is attached to PROCAST software,made some necessary amendments,found the high-temperature properties of B-grade steel in the database,compared with the C-grade steel which is got by experiments to make sure that the data is reliable.
In this paper,we simulated the flow and temperature fields of bolster by using the basic module of PROCAST,discussed the speed, temperature on the impact of defects to Bolster. Point out that chill and the feeder have the great impact on the defects. Through several times simulation,we got a reasonable distribution of chill and feeder. Then we Compared results with anycasting software,there is a conclusion that the results generated by the two software have a good consistency.
Crack as one of the defects have an important influence on the Bolster’s quality. In this paper, we described the causes of hot cracking, and used the stress module of PROCAST to predict hot-cracking、the distribution of thermal stress. There is a way to reduce the thermal stress effectively by setting a reasonable chill and feeder.
Determined the reasonable casting process by using numerical simulation, there is a guiding significance for the production for such complex Parts. At the same time, it will shorten the process cycle、reducing the cost of trial,and certainly the quality of casting will be guaranteed too.
本文在简要阐述铸造数值模拟技术基本原理基础上,介绍了PROCAST软件所采用的有限元方法建立的温度场、流场以及应力场的数学、物理模型和进行有限元离散求解,以及铸造缺陷的判定。
对PROCAST的使用者来说,复杂零件的网格划分是比较困难的事情,本文研究了CAD软件和前处理软件与PROCAST之间的接口问题。对比发现,用pro/e生成的面网格与PROCAST有较好的兼容性,对于复杂零件能较好的解决铸型与铸件、冷铁与铸件的网格一致性的问题。
热物性参数对模拟的准确性起到相当重要的作用,本文通过PROCAST软件自带的计算系统,通过必要的修正计算出B级钢的热物性参数,并通过查找数据得到B级钢的高温性能,同时与实验得出的C级钢数据比较,验证数据的可靠性。
本文利用PROCAST的基本模块,对摇枕流动场和温度场进行了模拟,讨论了速度、温度对摇枕缺陷的影响,阐明冷铁及冒口的布置对缺陷的影响最大,通过多次模拟确定比较合理的冷铁及冒口的分布。用Anycasting软件对结果进行了对比,发现两种软件得到的结果有较好的一致性。
裂纹作为摇枕缺陷之一,对摇枕的质量有重要影响,本文阐述了热裂产生的原因,并利用PROCAST的应力模块对摇枕进行了热裂倾向、热应力大小及分布进行了模拟,通过设置合理的冷铁,有效的降低了热应力。
通过数值模拟,确定了比较合理的铸造工艺,对这种复杂的零件的生产提供了指导意义,同时也缩短了工艺准备的周期,降低了试制成本,是得到合格铸件的有力保证。
Bolster as a key part in the Locomotive,in order to meet the heavy-duty and high-speed operating environment, we need high quality of bolster. From the production and reports, we know that the bolster main problems are shrinkage、cracks and other casting defects. Defects scattered in the bolster and could not be controlled. In light of these, we decided to design process of bolster by using numerical simulation techniques. This article is to analyze and simulate the casting process of bolster by using PROCAST software,then fix the casting process.
On the basis of the theory–numerical simulation technology for casting process, this article expounds how the PROCAST to detect temperature, fluid and stress field by mathematics and physics model through finite element method (FEM) so as to figure out casting defects.
To the users of PROCAST,it is difficult to mesh the complex parts. In this paper,we discussed the interface between the CAD software and pre-processing software with PROCAST. Finally we found that the surface mesh generated by pro/e have a better compatibility to PROCAST,we can got a good match between casting and mould、casting and chill for complex parts.
Thermophysical properties played an important role to the accurate simulation. We calculated the thermal parameters of B-grade steel by using the computing system which is attached to PROCAST software,made some necessary amendments,found the high-temperature properties of B-grade steel in the database,compared with the C-grade steel which is got by experiments to make sure that the data is reliable.
In this paper,we simulated the flow and temperature fields of bolster by using the basic module of PROCAST,discussed the speed, temperature on the impact of defects to Bolster. Point out that chill and the feeder have the great impact on the defects. Through several times simulation,we got a reasonable distribution of chill and feeder. Then we Compared results with anycasting software,there is a conclusion that the results generated by the two software have a good consistency.
Crack as one of the defects have an important influence on the Bolster’s quality. In this paper, we described the causes of hot cracking, and used the stress module of PROCAST to predict hot-cracking、the distribution of thermal stress. There is a way to reduce the thermal stress effectively by setting a reasonable chill and feeder.
Determined the reasonable casting process by using numerical simulation, there is a guiding significance for the production for such complex Parts. At the same time, it will shorten the process cycle、reducing the cost of trial,and certainly the quality of casting will be guaranteed too.
引文
[1]张洪武,关振群,李云鹏,顾元宪.有限元分析与CAE技术基础[M].北京:清华大学出版社,2004.
[2]熊守美,许庆彦,康进武.铸造过程模拟仿真技术[M].北京:机械工业出版社,2004.
[3]柳百成,荆涛.铸造工程的模拟仿真与质量控制[M].北京:机械工业出版社,2001.
[4]董湘怀.材料成形计算机模拟[M].北京:机械工业出版社,2002.
[5]薛学斌.B级钢转K2侧架铸造工艺分析[J].铸造,2005,(6):55-67.
[6] M. R. Barkhudarov. Advanced Simulation of the Flow and Heat Transfer Processes in Simultaneous Engineering [M].USA: Flow Science, Inc.,.
[7]模具实用技术丛书编委会.压铸模设计应用实例[M].北京:机械工业出版社,2005.
[8] Marcin Lipowiecki . Using simulation to solve current industrial casting problems [R].
[9] ESI GROUP.CASTING[EB/OL] .www.esi-group.com.
[10]热加工资讯网.热加工工艺模拟技术发展趋势[EB/OL]. www.rjggy.com.
[11]柳百成,许庆彦,熊守美.铸造过程的多尺度模拟研究进展[J].机械工程学报,2003,39(10):53-63.
[12]余小清,杨斌.铁道货车摇枕侧架探伤方法探讨[J].无损探伤,2006,30(1):12-14.
[13]白淑萍.K6转向架摇枕裂纹原因分析及改进措施[J].铁道技术监督,2007,35(3):21-22.
[14]陈同军.消除铁路货车用摇枕和侧架裂纹的实践[J].中国铸造装备与技术,1999,(4):32-33.
[15]管遵辉.转K2摇枕铸件裂纹产生原因分析及防止[J].铸造,2006,(11):55-58.
[16]陈雪峰.自硬呋喃树脂砂在解决摇枕侧架裂纹中的应用[J].机车车辆工艺,1999,(1):11-13.
[17]陈拥军.巴西米轨转向架摇枕的铸造工艺[J].铸造设备研究,2007,(2):20-23.
[18]崔世海.采用自硬呋喃树脂砂工艺生产摇枕、侧架缩尺的确定[J].铁道机车车辆人,2001,(4):4-5.
[19]方志平.侧架CAD/CAE/CAM技术研究:[D].黑龙江:哈尔滨理工大学.2005.
[20]王鸽鸽,韩建民,李卫京,杨智勇,王金勇.铁路货车转向架用摇枕铸造凝固模拟及工艺优化[J].铸造,2007(4):71-74.
[21]潘安霞,罗广思.侧架铸造缺陷分析及对策[J].煤矿机械,2006,27(5):831-832.
[22] ESI GROUP. Procast-help[M].ESI GROUP,2005.
[23]胡红军,杨明波,罗静,王春欢,陈康.ProCAST软件在铸造凝固模拟中的应用[J].材料科学与工艺,2006,14(3):293-295.
[24]侯延辉,成志强,冯威潮,柳葆生.Procast在铸造缩孔预测及其优化中的应用[J].中国水运,2007,7(3):67-69.
[25]于百库.PROCAST在澳车转向架上的应用:[D].黑龙江:哈尔滨理工大学.2005.
[26]赵云龙,王承志.前后处理软件与Procast接口方式的研究[J].沈阳理工大学报,2006,25(3):19-21.
[27]万曙雄.转K4摇枕的铸造工艺设计[J].机车车辆工艺,2004,(3):34-35.
[28]高金平.转K6侧架铸造工艺分析[J].铁道机车车辆工人,2006,(5):1-7.
[29]李先民.冒口的优化设计[J].四川轻化工学院学报,2002,15(3):37-40.
[30]朱昌盛,王智平,朱昌锋.基于ProCAST的铸钢大齿轮的热节分析[J].铸造技术,2004,25(2):97-98.
[31]周业明,李莉,胡志勇,李殿中.有限元模拟预测铸钢件的宏观缩孔缺陷[J].铸造,2001,50(12):743-745.
[32] P.V?yrynen1,S.Vapalahti,S.Louhenkilpi,L.Chatburn,M.Clark,T.Wagner.Tundish Flow Model Tuning and Validation : Steady State and Transient Casting Situations[J]. STEELSIM 2007,2007.
[33] Francis H, Harlow and J, Eddie Welch.The MAC Method: A computing Technique for Solving iscous. Incompressible, Transient Fluid Flow.Physics of Fluids[J].1965,8(12):2182-2190.
[34] A. Amsden, F .H. Harlow.The SMAC Method: A Numerical Technique for Calculating Incompressible Fluid Flows[J]. Los Alamos Laboratory Report,1970.
[35] B. W. Hirt, B. D. Nichols. Volume of fluid(VOF)Method for the Dynamics of Free Boundaries[J]. Journal of Computational Physics,1981,39(1):201-225.
[2]熊守美,许庆彦,康进武.铸造过程模拟仿真技术[M].北京:机械工业出版社,2004.
[3]柳百成,荆涛.铸造工程的模拟仿真与质量控制[M].北京:机械工业出版社,2001.
[4]董湘怀.材料成形计算机模拟[M].北京:机械工业出版社,2002.
[5]薛学斌.B级钢转K2侧架铸造工艺分析[J].铸造,2005,(6):55-67.
[6] M. R. Barkhudarov. Advanced Simulation of the Flow and Heat Transfer Processes in Simultaneous Engineering [M].USA: Flow Science, Inc.,.
[7]模具实用技术丛书编委会.压铸模设计应用实例[M].北京:机械工业出版社,2005.
[8] Marcin Lipowiecki . Using simulation to solve current industrial casting problems [R].
[9] ESI GROUP.CASTING[EB/OL] .www.esi-group.com.
[10]热加工资讯网.热加工工艺模拟技术发展趋势[EB/OL]. www.rjggy.com.
[11]柳百成,许庆彦,熊守美.铸造过程的多尺度模拟研究进展[J].机械工程学报,2003,39(10):53-63.
[12]余小清,杨斌.铁道货车摇枕侧架探伤方法探讨[J].无损探伤,2006,30(1):12-14.
[13]白淑萍.K6转向架摇枕裂纹原因分析及改进措施[J].铁道技术监督,2007,35(3):21-22.
[14]陈同军.消除铁路货车用摇枕和侧架裂纹的实践[J].中国铸造装备与技术,1999,(4):32-33.
[15]管遵辉.转K2摇枕铸件裂纹产生原因分析及防止[J].铸造,2006,(11):55-58.
[16]陈雪峰.自硬呋喃树脂砂在解决摇枕侧架裂纹中的应用[J].机车车辆工艺,1999,(1):11-13.
[17]陈拥军.巴西米轨转向架摇枕的铸造工艺[J].铸造设备研究,2007,(2):20-23.
[18]崔世海.采用自硬呋喃树脂砂工艺生产摇枕、侧架缩尺的确定[J].铁道机车车辆人,2001,(4):4-5.
[19]方志平.侧架CAD/CAE/CAM技术研究:[D].黑龙江:哈尔滨理工大学.2005.
[20]王鸽鸽,韩建民,李卫京,杨智勇,王金勇.铁路货车转向架用摇枕铸造凝固模拟及工艺优化[J].铸造,2007(4):71-74.
[21]潘安霞,罗广思.侧架铸造缺陷分析及对策[J].煤矿机械,2006,27(5):831-832.
[22] ESI GROUP. Procast-help[M].ESI GROUP,2005.
[23]胡红军,杨明波,罗静,王春欢,陈康.ProCAST软件在铸造凝固模拟中的应用[J].材料科学与工艺,2006,14(3):293-295.
[24]侯延辉,成志强,冯威潮,柳葆生.Procast在铸造缩孔预测及其优化中的应用[J].中国水运,2007,7(3):67-69.
[25]于百库.PROCAST在澳车转向架上的应用:[D].黑龙江:哈尔滨理工大学.2005.
[26]赵云龙,王承志.前后处理软件与Procast接口方式的研究[J].沈阳理工大学报,2006,25(3):19-21.
[27]万曙雄.转K4摇枕的铸造工艺设计[J].机车车辆工艺,2004,(3):34-35.
[28]高金平.转K6侧架铸造工艺分析[J].铁道机车车辆工人,2006,(5):1-7.
[29]李先民.冒口的优化设计[J].四川轻化工学院学报,2002,15(3):37-40.
[30]朱昌盛,王智平,朱昌锋.基于ProCAST的铸钢大齿轮的热节分析[J].铸造技术,2004,25(2):97-98.
[31]周业明,李莉,胡志勇,李殿中.有限元模拟预测铸钢件的宏观缩孔缺陷[J].铸造,2001,50(12):743-745.
[32] P.V?yrynen1,S.Vapalahti,S.Louhenkilpi,L.Chatburn,M.Clark,T.Wagner.Tundish Flow Model Tuning and Validation : Steady State and Transient Casting Situations[J]. STEELSIM 2007,2007.
[33] Francis H, Harlow and J, Eddie Welch.The MAC Method: A computing Technique for Solving iscous. Incompressible, Transient Fluid Flow.Physics of Fluids[J].1965,8(12):2182-2190.
[34] A. Amsden, F .H. Harlow.The SMAC Method: A Numerical Technique for Calculating Incompressible Fluid Flows[J]. Los Alamos Laboratory Report,1970.
[35] B. W. Hirt, B. D. Nichols. Volume of fluid(VOF)Method for the Dynamics of Free Boundaries[J]. Journal of Computational Physics,1981,39(1):201-225.