铝合金两体机座外套和导体铸造工艺数值模拟
摘要
两体机座铝外套是新型电力机车的零件之一,而铝合金导体是高压配电设备上重要部件之一。由于结构上的原因,两体机座铝外套和铝合金导体都比较容易在关键部位产生缩孔、缩松等缺陷。为确保两体机座铝外套的强度以及铝合金导体的导电性能,得到无缺陷的质量合格的铸件,并提高生产效率,有必要对其铸造工艺进行数值模拟,以便进行铸造工艺优化。
文中以两体机座铝外套和铝合金导体为研究对象,回顾了数值模拟的基本理论和铸造模拟软件ProCAST。结合铸造工艺的相关知识,对两体机座铝外套设计了两套方案,分别为敞口朝上浇注法和敞口朝下浇注法；对铝合金导体设置了七套方案(三种思路),包括安置暗冒口、追加外冷铁和改结构。
两体机座铝外套模拟结果表明：敞口朝上浇注法下,当在其下边缘处设置适当大小的暗冒口时,铸件内的缩松就会消失,得到的工艺出品率为45%。而在敞口朝下浇注法下,通过在中间厚处设置冷铁以及合适的暗冒口和保温冒口,可以有效的解决补缩问题,得到的工艺出品率为39.9%。通过后续的优化方案,进一步的优化了敞口朝下浇注法,发现当保温冒口设置为80mm,浇冒口设置为90mm时,铸件可以最合理有效补缩,工艺出品率到达48.6%。
铝合金导体模拟结果表明：砂型铸造下放置外冷铁或设置暗冒口的思路是可行的；在改结构思路下,砂型和金属型都获得了不错的效果,工艺出品率也得到了很好的保证,都在74%以上。通过对比各方案的特点,选择在砂型和金属型下改结构的思路进行优化,得出的最佳优化方案为金属型改结构的方案,选取的最佳冷却通道的直管和弯管的伸出长度分别为45mm和55mm。
通过Pro/E和ProCAST的使用,总结出了使用Pro/E画面网格,然后在ProCAST中进行体网格划分的改进方法,使得铸造模拟过程更加的顺利进行。通过本次模拟,两体机座铝外套在两套方案下都得到了不错的效果,在实际生产中也得到了充分验证；铝合金导体的七套方案成功做出了四套,特别是改结构方案的成功,将更有利于实际的生产。
Al alloy two-body seating coat is a part of new electric locomotive, and Al alloy conductor is one of the important components on high voltage distribution equipment. For structure reasons, Two-body seating coat and Al alloy conductor are easy to turn up defects in key areas, such as shrinkage, porosity shrinkage. To ensure that the two-body seating coat's strength and Al alloy conductor's electric conductivity, get no defect casting, and improve production efficiency, it is necessary to simulate the casting process for casting process optimization.
Based on Al alloy two-body seating coat and Al alloy conductor,The article reviews the basic theory of numerical simulation and casting simulation software ProCAST. Combined with the knowledge of casting technology, Al alloy two-body seating coat is designed two schemes, one is opening-up casting method, the other is opening-down casting method; Al alloy conductor has seven schemes (three ideas), including resettlement dark riser, additional external cold iron and change structure.
The simulation results of Al alloy two-body seating coat show that:On opening-up casting method, when set proper size riser on it inner under-edge, casting shrinkage will disappear, get the technology product yield about 45%. And on opening-down casting method, through set a cold iron in the middle of the thick, and suit dark riser and insulation riser, The feeding problem can be solved effectively, get the technology product yield about 39.9%. Through the optimization scheme, to optimize the opening-down casting method, when the insulation riser sets to 80mm, casting head 90mm, the casting can get more effective feeding, the technology product yield comes up to 48.6%.
The simulation results of Al alloy conductor show that:the idea of set cold iron and dark riser under the sand casting is feasible, in structural change, sand casting and metal casting are both taken very good guarantee, the technology product yield all at 74% above. Through comparing the characteristics of each scheme, choose the structural change scheme of sand casting and metal casting to optimize. the best optimization scheme is metal casting, the selection is straight Cooling channel pipe length 45mm and bent Cooling channel pipe length 55mm.
Through the use of Pro/E and ProCAST, sum up the improvement methods that using Pro/E draws centredgrating and ProCAST draws volume meshing, then make the casting simulation process more smoothly. Through the simulation, Two schemes of Al alloy two-body seating coat both have good effect, also well proved in practical production; Four of seven schemes are success in Al alloy conductor, especially the success of structural change scheme, will be more beneficial for the actual production.
文中以两体机座铝外套和铝合金导体为研究对象,回顾了数值模拟的基本理论和铸造模拟软件ProCAST。结合铸造工艺的相关知识,对两体机座铝外套设计了两套方案,分别为敞口朝上浇注法和敞口朝下浇注法；对铝合金导体设置了七套方案(三种思路),包括安置暗冒口、追加外冷铁和改结构。
两体机座铝外套模拟结果表明：敞口朝上浇注法下,当在其下边缘处设置适当大小的暗冒口时,铸件内的缩松就会消失,得到的工艺出品率为45%。而在敞口朝下浇注法下,通过在中间厚处设置冷铁以及合适的暗冒口和保温冒口,可以有效的解决补缩问题,得到的工艺出品率为39.9%。通过后续的优化方案,进一步的优化了敞口朝下浇注法,发现当保温冒口设置为80mm,浇冒口设置为90mm时,铸件可以最合理有效补缩,工艺出品率到达48.6%。
铝合金导体模拟结果表明：砂型铸造下放置外冷铁或设置暗冒口的思路是可行的；在改结构思路下,砂型和金属型都获得了不错的效果,工艺出品率也得到了很好的保证,都在74%以上。通过对比各方案的特点,选择在砂型和金属型下改结构的思路进行优化,得出的最佳优化方案为金属型改结构的方案,选取的最佳冷却通道的直管和弯管的伸出长度分别为45mm和55mm。
通过Pro/E和ProCAST的使用,总结出了使用Pro/E画面网格,然后在ProCAST中进行体网格划分的改进方法,使得铸造模拟过程更加的顺利进行。通过本次模拟,两体机座铝外套在两套方案下都得到了不错的效果,在实际生产中也得到了充分验证；铝合金导体的七套方案成功做出了四套,特别是改结构方案的成功,将更有利于实际的生产。
Al alloy two-body seating coat is a part of new electric locomotive, and Al alloy conductor is one of the important components on high voltage distribution equipment. For structure reasons, Two-body seating coat and Al alloy conductor are easy to turn up defects in key areas, such as shrinkage, porosity shrinkage. To ensure that the two-body seating coat's strength and Al alloy conductor's electric conductivity, get no defect casting, and improve production efficiency, it is necessary to simulate the casting process for casting process optimization.
Based on Al alloy two-body seating coat and Al alloy conductor,The article reviews the basic theory of numerical simulation and casting simulation software ProCAST. Combined with the knowledge of casting technology, Al alloy two-body seating coat is designed two schemes, one is opening-up casting method, the other is opening-down casting method; Al alloy conductor has seven schemes (three ideas), including resettlement dark riser, additional external cold iron and change structure.
The simulation results of Al alloy two-body seating coat show that:On opening-up casting method, when set proper size riser on it inner under-edge, casting shrinkage will disappear, get the technology product yield about 45%. And on opening-down casting method, through set a cold iron in the middle of the thick, and suit dark riser and insulation riser, The feeding problem can be solved effectively, get the technology product yield about 39.9%. Through the optimization scheme, to optimize the opening-down casting method, when the insulation riser sets to 80mm, casting head 90mm, the casting can get more effective feeding, the technology product yield comes up to 48.6%.
The simulation results of Al alloy conductor show that:the idea of set cold iron and dark riser under the sand casting is feasible, in structural change, sand casting and metal casting are both taken very good guarantee, the technology product yield all at 74% above. Through comparing the characteristics of each scheme, choose the structural change scheme of sand casting and metal casting to optimize. the best optimization scheme is metal casting, the selection is straight Cooling channel pipe length 45mm and bent Cooling channel pipe length 55mm.
Through the use of Pro/E and ProCAST, sum up the improvement methods that using Pro/E draws centredgrating and ProCAST draws volume meshing, then make the casting simulation process more smoothly. Through the simulation, Two schemes of Al alloy two-body seating coat both have good effect, also well proved in practical production; Four of seven schemes are success in Al alloy conductor, especially the success of structural change scheme, will be more beneficial for the actual production.
引文
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