CN106407547A - Numerical simulation method for aiming at casting residual stress of anisotropic material - Google Patents
Numerical simulation method for aiming at casting residual stress of anisotropic material Download PDFInfo
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Abstract
The invention discloses a numerical simulation method for aiming at the casting residual stress of an anisotropic material, and is used for solving the technical problem that an existing simulation method of the casting residual stress has a narrow application range. The technical scheme of the numerical simulation method is that ProCAST software is used for carrying out numerical simulation on the temperature field of a cast solidifying and cooling process, the temperature field is converted into a temperature amplitude value which can be accepted by ABAQUS, and an ABAQUS data file INP file can be generated; the converted temperature amplitude value is copied to the generated ABAQUS data file INP file to generate a new INP file; and for the generated new INP file, an ABAQUS Command is used for finishing the numerical simulation of the casting residual stress of the anisotropic material. The method combines the respective advantages of the ProCAST software and the ABAQUS software, the residual stress of the anisotropic material cast in a casting process can be accurately simulated, and accuracy is above 81%.
Description
Technical field
The present invention relates to a kind of analogy method of casting residual stress, particularly to a kind of for anisotropic material casting
The method for numerical simulation of residual stress.
Background technology
Anisotropic material is applied increasingly extensive in Modern Manufacturing Industry, and this kind of material is due on each microcosmic direction
Hot physical property performance and mechanical property are inconsistent, lead to heat transfer in casting process in all directions for this material and shrink change
Shape all can be inconsistent, so that the casting stress distribution of foundry goods is difficult to determine, such as single crystal turbine blade in aero-engine
Casting residual stress distribution problem is to develop a significant obstacle of high thrust-weight ratio engine.Currently for casting residual stress
Numerical simulation main software is ProCAST, but the shortcoming of this software to be material depot incomplete, can only pin in terms of stress field simulation
Numerical simulation is carried out to isotropic material foundry goods.
Document " FE prediction of residual stresses of investment casting in a
Bottom Core Vane under equiaxed cooling, Journal of Manufacturing Processes,
Vol13 (1), January 2011, Pages30 40 " gives and a kind of simulates casting residual stress using ABAQUS software
New method.ProCAST is written as ABAQUS receptible UTEMP subprogram by the method to the temperature field of guide vane, should
Temperature field is loaded one by one to each grid node of guide vane, carries out order Thermal-mechanical Coupling, to solve guide vane
Casting residual stress, acquired results are preferable with the actual measurement goodness of fit.But the method is not particularly suited for simulating anisotropy material
The casting residual stress of material, because every kind of anisotropic material has its particularity, in order to accurately express its characteristic, general root
To write user's material UMAT subprogram according to its characteristic, and each simulation document can only add a subprogram in ABAQUS,
Therefore said method can not carry out numerical simulation to temperature field UTEMP and material subprogram UMAT simultaneously, has larger limitation
Property.Additionally, said method is written as to temperature field, and UTEMP subroutine procedure is very loaded down with trivial details, do not possess what general mass was processed
Ability, also limit its range.
In sum, the method being directed to casting residual stress at this stage is not particularly suited for anisotropic material, the scope of application
Narrow.
Content of the invention
In order to overcome the shortcomings of the analogy method narrow application range of existing casting residual stress, the present invention provides one kind to be directed to
The method for numerical simulation of anisotropic material casting residual stress.The method utilizes ProCAST software to casting solidification and cooling
Process temperature field carries out numerical simulation, and temperature field is converted into ABAQUS receptible temperature amplitude, in Viewer-CAST
By in running gate system in addition to body of heater each assembly respectively with INP file derive, generate ABAQUS data file INP file；To pass through
The temperature amplitude of conversion is copied in the ABAQUS data file INP file of generation, generates new INP file；According to foundry goods material
The characteristic of material writes anisotropic material subprogram UMAT file using Fortran language；For generating new INP file, tie
Zygote program UMAT file, completes the residual stress Numerical-Mode to anisotropic material foundry goods using ABAQUS Command order
Intend.The method combines ProCAST software and can have two kinds of abundant material depot compared with accurate simulation casting temperature field and ABAQUS
Advantage, using the temperature field translation interface of user's material UMAT subprogram and high reliability, can accurately simulation respectively to different
The residual stress that property material cast produces in casting process, rate of accuracy reached to more than 81%.
The technical solution adopted for the present invention to solve the technical problems：One kind is directed to anisotropic material casting residual stress
Method for numerical simulation, be characterized in comprising the following steps：
Step one, using ProCAST software, numerical simulation is carried out to casting solidification and cooling procedure temperature field, and utilize
Casting temperature field is derived by the poster processing soft Viewer-CAST of ProCAST software；
Step 2, in MATLAB operating environment, using the temperature field translation interface writing, by step one gained temperature
Field is converted into ABAQUS receptible temperature amplitude, and generates the set of node of foundry goods and predefined field using translation interface；
Step 3, in Viewer-CAST by running gate system medium casting, formwork assemblies respectively with INP file derive, and
Ressemble in ABAQUS, add boundary condition, change finite element grid type, generate ABAQUS data file INP file；
Step 4, temperature amplitude, set of node and predefined field that step 2 gained is changed are copied to step 3 and are given birth to
In the ABAQUS data file INP file becoming, generate new INP file；
Step 5, anisotropic material subprogram UMAT literary composition is write using Fortran language according to the characteristic of casting material
Part；
Step 6, new INP file is generated for step 4, in conjunction with step 5 gained UMAT subprogram, using ABAQUS
Command order completes the residual stress numerical simulation to anisotropic material foundry goods.
The invention has the beneficial effects as follows：The method is entered to casting solidification and cooling procedure temperature field using ProCAST software
Row numerical simulation, and temperature field is converted into ABAQUS receptible temperature amplitude, by running gate system in Viewer-CAST
In addition to body of heater, each assembly is derived with INP file respectively, generates ABAQUS data file INP file；By the temperature width through conversion
Value is copied in the ABAQUS data file INP file of generation, generates new INP file；Characteristic according to casting material utilizes
Anisotropic material subprogram UMAT file write in Fortran language；For generating new INP file, in conjunction with subprogram UMAT
File, completes the residual stress numerical simulation to anisotropic material foundry goods using ABAQUS Command order.The method is tied
Close ProCAST software and can have abundant two kinds of advantages of material depot compared with accurate simulation casting temperature field and ABAQUS, using use
Family material UMAT subprogram and the temperature field translation interface of high reliability, can accurately simulation anisotropic material foundry goods exist
The residual stress producing in casting process, rate of accuracy reached to more than 81%.
With reference to the accompanying drawings and detailed description the present invention is elaborated.
Brief description
Fig. 1 is the flow chart of the method for numerical simulation that the present invention is directed to anisotropic material casting residual stress.
Fig. 2 is I-beam illustraton of model in the inventive method embodiment.
Fig. 3 is conversion main interface figure in temperature field in the inventive method embodiment.
Specific embodiment
Reference picture 1-3.The present invention is directed to the method for numerical simulation concrete steps of anisotropic material casting residual stress such as
Under：
The first step, first with 3 d modeling software, whole running gate system is modeled, including moulds such as foundry goods and cores
Type；Using Hypermesh software, pre-treatment is carried out to FEM (finite element) model, two-dimensional grid is carried out to each assembly using tetrahedron element
Divide, local cypher process is carried out to the grid at foundry goods key position or structural mutation；In ProCAST pre-processing software
In MeshCAST, each part carried out assembling, mesh quality inspection, generate formwork and volume mesh divides etc., set in PreCAST
Put the hot physical property of casting material and and the boundary condition such as mechanics parameter, the coefficient of heat transfer and heat-transfer surface setting, fixation and plane of symmetry setting
Setting, completes whole casting process is emulated；By casting temperature field in ProCAST the poster processing soft Viewer-CAST
Derived with * .ntl form, in addition to body of heater, foundry goods, formwork and other assemblies are derived with * .inp form respectively.
Second step, using ProCAST and ABAQUS temperature field translation interface, the temperature field derived in the first step is carried out
Conversion, obtains ABAQUS temperature amplitude, and generates set of node and predefined field.
3rd step, by the * .inp file of the foundry goods derived in the first step, formwork and other assemblies be directed respectively into
Ressembled in ABAQUS, setting static(al) steady-state analysis step, in addition to heat transfer boundary condition, remaining boundary condition setting all with
ProCAST is consistent, and the CAE obtaining file is derived with * .inp form.
4th step, by ABAQUS temperature amplitude in second step, generate set of node and predefined field is copied to the 3rd step respectively
The relevant position of the * .inp file of gained.
5th step, write the sub- journey of ABAQUS user material UMAT using Fortran language for foundry goods anisotropic material
Sequence * .for file, and debug successfully in Visual-studio.
6th step, the * * .inp file that the 4th step obtains being obtained with the 5th step using ABAQUS Command order
.for file joins together to carry out numerical simulation to casting stress field.
Application Example：
By the use of solving I-beam residual stress as a specific embodiment, this I-beam material is anisotropy to the present invention
Material DD6, forging type is directional solidification, with reference to this embodiment, the present invention is carefully stated as follows：
The first step, using UG software, three-dimensional modeling is carried out to I-beam running gate system, by each assembly respectively with * .iges lattice
Formula derives；Above-mentioned * .iges file is directed respectively in Hypermesh software and carries out pre-treatment, using tetrahedron element to each group
Part carries out two-dimensional grid division, and grid basic size is 1mm, derives each part of gained with * .out form respectively；By the * obtaining
.out file is directed respectively into and carries out assembling to ProCAST, mesh quality inspection, generates formwork and volume mesh divides etc., entirely
Model comprises 38137 nodes, 161366 units；Subsequently each assembly is carried out with material imparting, wherein casting material is high temperature
, all using [001] directional performance parameter, formwork, core material are silica sand, cold copper for alloy DD6, set hot physical property and mechanics parameter
Material is fine copper, and in addition to foundry goods, remaining component is all set to rigid body, and foundry goods is 2000W/ with the interface heat exchange coefficient of other assemblies
m2.K, the interface heat exchange coefficient between remaining component is 500W/m2.K；In boundary condition setting, to formwork, core and cold copper
It is fixed, the external thermal emissivity rate of whole formwork outer surface is 0.85, and cold copper initial temperature is 20 DEG C, foundry goods, formwork and core
Initial temperature be 1550 DEG C, whole running gate system acceleration of gravity be 9.8m/s2, acceleration direction is [001] direction；Body of heater
It is divided into three parts, wherein high-temperature region temperature is 1550 DEG C, and radiance is 0.9, and middle warm area temperature is 900 DEG C, and radiance is
0.6, low-temperature space temperature is 20 DEG C, and radiance is 0.5, and the withdrawing rate of whole body of heater is 0.8cm/min, and pull direction is
[001] direction, subsequently can be emulated；After ProCAST emulation terminates, by casting temperature field with * in Viewer-CAST
.ntl form is derived, and is then switched to Mesh pattern, and foundry goods, formwork and core are derived with * .inp form respectively.
Second step, the * .ntl temperature field obtaining the first step are entered row format in the temperature field translation interface writing and are turned
Change, generate and obtain ABAQUS temperature amplitude, and generate set of node and predefined field, wherein, phrasing points' number goes 2000, temperature field row
Number takes 38, and the total nodes of foundry goods are 11888, so both can generate the * .txt of ABAQUS temperature amplitude, set of node and predefined field
File.
3rd step, the * .inp file obtaining the first step re-start assembling, in material properties module ABAQUS
In, casting material Selection and call subprogram UMAT, formwork, core and cold copper product are all configured by parameter in ProCAST, if
Determine static(al) steady-state analysis step, in addition to heat exchange, remaining all kinds of boundary condition is all consistent with ProCAST setting, wherein, respectively contacts to equal
Using find contact to method select, this running gate system model is derived with * .inp form.
4th step, will the ABAQUS that generate in second step temperature amplitude, generate set of node and the three * .txt in predefined field literary composition
Part is copied to the relevant position of the * .inp file of the 3rd step gained respectively, obtains residual-stress.inp file.
5th step, write ABAQUS user's material UMAT subprogram using Fortran language for DD6 anisotropic material
Umat.for file, and debug successfully in Visual-studio.
6th step, the residual-stress.inp file the 4th step being obtained using ABAQUS Command order with
The umat.for file that 5th step obtains is joined together, using abaqus job=residual-stress user=
Umat.for order carries out numerical simulation to casting stress field.
Result shows, due to being hindered by core when I-beam shrinks during cooling, I-beam pars intermedia
Position produces larger residual stress, and relatively small away from I-beam position stress value, additionally, the stress of four sharp corners is due to being subject to
To the impact of structure, stress value maximum, meet residual stress distribution rule in casting process.
In a word, the temperature field translation interface of user's material UMAT subprogram and high reliability is combined by the present invention, solution
Traditional method of having determined to the problem of anisotropic material casting residual stress numerical simulation, and can not be cast for various differences
The mode of making residual stress of casting is carried out numerical simulation, finds through contrasting with measured value, and this method simulation accuracy rate is up to
More than 81%, and applied widely.
Claims (1)
1. a kind of method for numerical simulation for anisotropic material casting residual stress is it is characterised in that comprise the following steps：
Step one, using ProCAST software, numerical simulation is carried out to casting solidification and cooling procedure temperature field, and utilize
Casting temperature field is derived by the poster processing soft Viewer-CAST of ProCAST software；
Step 2, in MATLAB operating environment, using the temperature field translation interface writing, step one gained temperature field is turned
Change ABAQUS receptible temperature amplitude into, and generate the set of node of foundry goods and predefined field using translation interface；
Step 3, in Viewer-CAST by running gate system medium casting, formwork assemblies respectively with INP file derive, and
Ressemble in ABAQUS, add boundary condition, change finite element grid type, generate ABAQUS data file INP file；
Step 4, temperature amplitude, set of node and predefined field that step 2 gained is changed are copied to what step 3 was generated
In ABAQUS data file INP file, generate new INP file；
Step 5, anisotropic material subprogram UMAT file is write using Fortran language according to the characteristic of casting material；
Step 6, new INP file is generated for step 4, in conjunction with step 5 gained UMAT subprogram, using ABAQUS
Command order completes the residual stress numerical simulation to anisotropic material foundry goods.
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Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN111331077A (en) * | 2020-04-27 | 2020-06-26 | 泰州市金鹰精密铸造有限公司 | Size control method for casting high-silicon light hypereutectic aluminum-silicon alloy product |
| CN111931397A (en) * | 2020-07-01 | 2020-11-13 | 中国科学院金属研究所 | Numerical simulation method of reticular reinforced metal matrix composite material |
| CN112883518A (en) * | 2021-03-09 | 2021-06-01 | 西安石油大学 | Method for predicting residual stress and deformation of TIG additive and rolling composite manufactured part |
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Cited By (3)
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Application publication date: 20170215 |