铝-7石墨半固态浆料比重偏析控制的数值模拟
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摘要
铝-7石墨复合材料兼有铝基体导热快、石墨润滑性能优良等特点,是制造新型钢背轴瓦的理想材料,需求领域广泛。对于铝-7石墨复合材料,石墨的分布状态直接决定其综合性能的好坏,是该领域的首要问题。本文采用流体模拟软件FLUENT对机械搅拌法、电磁搅拌法和机械电磁复合搅拌法制备铝石墨半固态浆料的过程进行了模拟研究,并通过实际验证得到了合理的制备工艺,本文具体研究如下:
1、针对目前粘度模型存在模拟误差较大的问题,本文确定了适合于FLUENT软件数值模拟粘度系数的合理范围,提高了模拟精度。
2、通过对石墨颗粒分布的模拟,得出电磁搅拌频率和搅拌桨叶的倾斜角度。
3、对机械搅拌、电磁搅拌和机械电磁复合搅拌制备铝-7石墨半固态浆料的过程进行了计算机模拟和敏感性分析,得出网格划分密度对模拟的影响
4、通过对湍流动能、搅拌时间、搅拌温度、搅拌转速、电磁电流和石墨颗粒分布等进行模拟和分析对比,得出进行机械电磁复合搅拌时石墨的浓度差最小,是较为合理的搅拌方法,同时得出并通过实验确定了合理的搅拌工艺参数,为实际生产提供了参考。
The aluminum-7graphite composite material is the ideal functional material to make the new bearings because the Al substrate has the good thermal conduction and the graphite has the good lubricant property, so the Aluminum-graphite composite has the wider application. The distribution of graphite determines the performance of the aluminum-7graphite composite material, and distribution is the chief issue in the field. In this paper, the mechanical stirring method、the electromagnetic stirring method and the mechanical and electromagnetic composite stirring method were studied by the simulation software FLUENT to prepare the semi-solid slurry of Aluminum-graphite material. The specific studies of this paper are as followings:
1、To solve the inaccuracy of the simulation in the viscous model, this paper definites the reasonable scope of the viscous modules in the simulation which is if fit for the simulation software FLUENT to raise the accuracy of the simulation.
2、The paper gets the frequency of the electromagnetic stirring and the tilt angle of the blade through simulating the distribution of the graphite particles.
3、The paper gets the result that the density of the mesh has influence on the simulation through simulating and the analyzing the sensibility of the mechanical stirring method、the electromagnetic stirring method and the mechanical and electromagnetic composite stirring method.
4、The paper gets that the best stirring method is the mechanical and electromagnetic composite stirring method and also gets the best process parameters of the stirring method through the analysis of the turbulence kinetic energy、the stirring time、the stirring temperature、the stirring velocity、the electromagnetic stirring current、the rheological properties and the distribution of graphite particles, so as to offer the reference to the manufacture.
1、针对目前粘度模型存在模拟误差较大的问题,本文确定了适合于FLUENT软件数值模拟粘度系数的合理范围,提高了模拟精度。
2、通过对石墨颗粒分布的模拟,得出电磁搅拌频率和搅拌桨叶的倾斜角度。
3、对机械搅拌、电磁搅拌和机械电磁复合搅拌制备铝-7石墨半固态浆料的过程进行了计算机模拟和敏感性分析,得出网格划分密度对模拟的影响
4、通过对湍流动能、搅拌时间、搅拌温度、搅拌转速、电磁电流和石墨颗粒分布等进行模拟和分析对比,得出进行机械电磁复合搅拌时石墨的浓度差最小,是较为合理的搅拌方法,同时得出并通过实验确定了合理的搅拌工艺参数,为实际生产提供了参考。
The aluminum-7graphite composite material is the ideal functional material to make the new bearings because the Al substrate has the good thermal conduction and the graphite has the good lubricant property, so the Aluminum-graphite composite has the wider application. The distribution of graphite determines the performance of the aluminum-7graphite composite material, and distribution is the chief issue in the field. In this paper, the mechanical stirring method、the electromagnetic stirring method and the mechanical and electromagnetic composite stirring method were studied by the simulation software FLUENT to prepare the semi-solid slurry of Aluminum-graphite material. The specific studies of this paper are as followings:
1、To solve the inaccuracy of the simulation in the viscous model, this paper definites the reasonable scope of the viscous modules in the simulation which is if fit for the simulation software FLUENT to raise the accuracy of the simulation.
2、The paper gets the frequency of the electromagnetic stirring and the tilt angle of the blade through simulating the distribution of the graphite particles.
3、The paper gets the result that the density of the mesh has influence on the simulation through simulating and the analyzing the sensibility of the mechanical stirring method、the electromagnetic stirring method and the mechanical and electromagnetic composite stirring method.
4、The paper gets that the best stirring method is the mechanical and electromagnetic composite stirring method and also gets the best process parameters of the stirring method through the analysis of the turbulence kinetic energy、the stirring time、the stirring temperature、the stirring velocity、the electromagnetic stirring current、the rheological properties and the distribution of graphite particles, so as to offer the reference to the manufacture.
引文
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[17]郭晓凤,王承志,张玉妥,黄勇.铝合金半固态浆料制备过程的电磁-流体数值模拟.铸造设备研究,2007,1:19-22
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[19]宋月兰,多层桨搅拌槽内气-液两相流的数值模拟,北京化工大学硕士研究生论文,2006
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[25]王福军.计算流体动力学分析--CFD软件原理与应用.北京:清华大学出版社,2005
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[27]周志华,毛卫民,刘政等.半固态AlSi4Mg2铝合金的稳态流变性能.材料研究学报,2006,20(1):5-8
[28]侯栓弟,张政,王英琛,施力田.涡轮桨搅拌槽流动长数值模拟.化工学报,2001,52(3):241-246
[29]谢德馨,白保东,等.三维涡流场的有限元分析.北京:机械工业出版社,2001
[30]林建中.液-固两相拟序涡流及其稳定性.北京:清华大学出版社,2003
[31]岳湘安.液-固两相流基础,北京:石油工业出版社,1996
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[34]杨玲,刘昌明,左宏志.电磁搅拌制备ZL112Y铝合金流变半固态浆料的实验及模拟研究.铝加工,2007,4:10-13
[35]李剑超,崔建忠,王宝峰,麻永林.低频电磁铸造6063铝合金的数值模拟和实验研究.特种铸造及有色合金,2006,26(2):87-89
[36]李军文,王晓艳.机械搅拌对Al-Si合金凝固组织的影响及其模拟实验.铸造,2006,55(7):742-745
[37]徐跃,康永林,王朝辉.机械搅拌制备半固态浆料固相颗粒形貌的研究.特种铸造及有色合金,2006,26(1):36-38
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