CN106845007A - A kind of method for lifting high-pressure casting cavity filling process CAE analysis precision - Google Patents
A kind of method for lifting high-pressure casting cavity filling process CAE analysis precision Download PDFInfo
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- CN106845007A CN106845007A CN201710083171.9A CN201710083171A CN106845007A CN 106845007 A CN106845007 A CN 106845007A CN 201710083171 A CN201710083171 A CN 201710083171A CN 106845007 A CN106845007 A CN 106845007A
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- 238000005266 casting Methods 0.000 title claims abstract description 64
- 238000004458 analytical method Methods 0.000 title claims abstract description 51
- 238000005429 filling process Methods 0.000 title claims abstract description 29
- 238000000034 method Methods 0.000 title claims abstract description 19
- 238000004088 simulation Methods 0.000 claims abstract description 22
- 238000004519 manufacturing process Methods 0.000 claims abstract description 19
- 238000012800 visualization Methods 0.000 claims abstract description 6
- 239000002893 slag Substances 0.000 claims abstract description 5
- 230000000052 comparative effect Effects 0.000 claims abstract description 4
- 239000000463 material Substances 0.000 claims description 13
- 238000001816 cooling Methods 0.000 claims description 10
- 238000007711 solidification Methods 0.000 claims description 9
- 238000012546 transfer Methods 0.000 claims description 7
- 230000008569 process Effects 0.000 claims description 4
- 239000012774 insulation material Substances 0.000 claims description 3
- 229910052751 metal Inorganic materials 0.000 claims description 3
- 239000002184 metal Substances 0.000 claims description 3
- 230000007547 defect Effects 0.000 abstract description 8
- 238000004364 calculation method Methods 0.000 abstract description 6
- 238000004512 die casting Methods 0.000 abstract description 3
- 238000013461 design Methods 0.000 abstract description 2
- IXSZQYVWNJNRAL-UHFFFAOYSA-N etoxazole Chemical compound CCOC1=CC(C(C)(C)C)=CC=C1C1N=C(C=2C(=CC=CC=2F)F)OC1 IXSZQYVWNJNRAL-UHFFFAOYSA-N 0.000 abstract description 2
- 238000005457 optimization Methods 0.000 abstract 1
- 229910052782 aluminium Inorganic materials 0.000 description 17
- 239000004411 aluminium Substances 0.000 description 17
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 17
- 239000007788 liquid Substances 0.000 description 17
- 230000008023 solidification Effects 0.000 description 4
- 229910000838 Al alloy Inorganic materials 0.000 description 3
- 230000000630 rising effect Effects 0.000 description 2
- 238000012356 Product development Methods 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000005496 eutectics Effects 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000007920 subcutaneous administration Methods 0.000 description 1
- 230000000007 visual effect Effects 0.000 description 1
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F30/00—Computer-aided design [CAD]
- G06F30/30—Circuit design
- G06F30/36—Circuit design at the analogue level
- G06F30/367—Design verification, e.g. using simulation, simulation program with integrated circuit emphasis [SPICE], direct methods or relaxation methods
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F2119/00—Details relating to the type or aim of the analysis or the optimisation
- G06F2119/18—Manufacturability analysis or optimisation for manufacturability
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- General Engineering & Computer Science (AREA)
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Abstract
The present invention provides a kind of method for lifting high-pressure casting cavity filling process CAE analysis precision, belongs to casting computer numerical simulation field.Concretely comprise the following steps：Step one, the high pressure cavity filling process that casting is simulated with CAE software；CAE analysis parameter is set further according to the technique in actual production, CAE simulations are carried out to high-pressure casting process；Step 2, the high pressure cavity filling process that casting is shot using high-pressure casting visualization device；Step 3, by CAE analysis result and actual photographed Comparative result, find out the principal element that influence CAE analysis fill type precision, correct CAE analysis |input paramete, improve CAE analysis precision.The present invention can accurately find out in CAE sunykatuib analyses with the incongruent place of actual state, the reason for targetedly analysis difference is present, by changing CAE analog parameter amendment numerical simulation calculation models, revised numerical simulation calculation model is applied to baroque casting again, optimization die casting system, avoid because of the improper generation trapped gas of die casting system design, volume gas, misrun and oxide slag inclusion etc. fill type defect.
Description
Technical field
The invention belongs to cast computer numerical simulation field, and in particular to Mold Filling Process CAE analysis method.
Background technology
High-pressure casting process is due to being, in high pressure, high speed retrofilling die cavity, inevitably the air in die cavity to be wrapped
In cast-internal, subcutaneous blowhole is formed.In high-pressure casting production, more than 30% is up to by the casting wasted product rate for filling type generation, made
Into the significant wastage of human and material resources, cost and time.
Existing computer numerical simulation（CAE）The visual of casting filling and solidification is realized, engineering can be helped
Issuable defect in teacher's look-ahead filling and solidification processess, and take measures to control defect in time.But due to Numerical-Mode
Intend the uncertainty of parameter so that numerical simulation result has deviation with actual result, and mold filling simulation analysis precision is relatively low.If
CAE result of calculations and casting result only be can only see into the defect phenomenon after cooling to mark, and do not know that cavity filling process
In real-time status, so being difficult to Accurate Prediction as stomata, cold shut, misrun etc. fill type defect, CAE mold filling simulation analysis precisions
It is badly in need of lifting.
The content of the invention
The present invention is intended to provide a kind of method for lifting high-pressure casting cavity filling process CAE analysis precision, type is filled by CAE simulations
Result is analyzed with the filling mould states captured by high-speed camera, accurately find out in CAE sunykatuib analyses with actual shape
The CAE analysis precision in type stage is filled in the incongruent place of condition, lifting high-pressure casting, instructs setting for high-pressure casting mould running gate system
Meter.
A kind of method for lifting high-pressure casting cavity filling process CAE analysis precision, concretely comprises the following steps：
Step one, the high pressure cavity filling process that casting is simulated with CAE software：The threedimensional model of casting is imported first in CAE software
And material properties；CAE analysis parameter is set further according to the technique in actual production, CAE simulations are carried out to high-pressure casting process；
Step 2, the high pressure cavity filling process that casting is shot using high-pressure casting visualization device；
Step 3, by CAE analysis result and actual photographed Comparative result, find out the principal element that influence CAE analysis fill type precision,
Amendment CAE analysis |input paramete, improves CAE analysis precision；Specially：Mold temperature and reality first in contrast CAE analysis
Mold temperature difference in production, if exceeding temperature difference threshold value, cooling parameter in adjustment CAE checks the cooling in mould
Whether the cool time that pipe is set is consistent with practical condition；If inconsistent, repaiied according to the cool time in actual production
Just；If cool time beat is consistent, further ensure that the heat transfer coefficient in CAE databases is consistent with actual heat transfer coefficient；
If the mold temperature in CAE analysis is not above temperature difference threshold value with the mold temperature difference in actual production, right
Than filling mould states in CAE, whether trend, the hyperbar position for filling type order, bubble and slag inclusion are consistent with actual photographed result；
If consistent, casting, the matching precision of mould in threedimensional model and actual production are continued checking for, terminate comparison process；If differing
Cause, check the mold filling temperature and environment temperature set in CAE, if be consistent with actual mold filling temperature and environment temperature, if not
Symbol, then correct temperature parameter, if being consistent, further combined with crystalline phase figure and molten metal temperature conditionss adjustment viscosity coefficient and temperature
The physical parameters such as degree-solidification rate curve；
After the threedimensional model of casting and material properties are changed each time, it is required for CAE analysis result and actual photographed result weight
New contrast, until the high pressure cavity filling process of CAE simulation casting is consistent with type situation is actually filled, the physical parameter that will be changed is preserved.
Specifically, the part and material of the material properties assignment include：Casting, mould, core, sprue cup, stalk,
Pressure chamber, drift, rising head, running channel, ingate, overflow launder, blast pipe, cooling tube, insulation material.
Specifically, the temperature range of temperature difference threshold value is set to ± 10 DEG C.
The present invention is contrasted CAE simulation cavity filling process with the cavity filling process captured by high-speed camera, accurate to search
Go out in CAE sunykatuib analyses with the incongruent place of actual state, targetedly analyze difference the reason for exist, by changing CAE
Analog parameter amendment numerical simulation calculation model, then revised numerical simulation calculation model is applied to baroque casting
Part, the issuable defect of mold filling process of casting is accurately predicted by CAE analysis, optimizes die casting system, it is to avoid because of mould
The tool improper generation trapped gas of Design of Runner System, volume gas, misrun and oxide slag inclusion etc. fill type defect；Type is filled for what is be not avoided that
Defect, can accurately also predict its classification and generating unit, so as to instruct technologist to solve quality using most accurate method
Problem, shortens the new product development cycle, improves product yield, saves Foundry Production cost.
Brief description of the drawings
Fig. 1 is flow chart of the method for the present invention；
Fig. 2 is CAE simulated high-pressures Mold Filling Process figure of the invention；
Fig. 3 is that visualization device of the invention shoots high-pressure casting cavity filling process figure；
Fig. 4 is the high-pressure casting cavity filling process figure after present invention modification CAE analog parameters.
Specific embodiment
As shown in figure 1, a kind of method for lifting high-pressure casting cavity filling process CAE analysis precision, concretely comprises the following steps：
Step one, the high pressure cavity filling process that casting is simulated with CAE software：The threedimensional model of casting is imported first in CAE software
And material properties；CAE analysis parameter is set further according to the technique in actual production, CAE simulations are carried out to high-pressure casting process.Material
Expecting the part and material of attribute assignment includes：Casting, mould, core, sprue cup, stalk, pressure chamber, drift, rising head, running channel,
Ingate, overflow launder, blast pipe, cooling tube, the attribute of insulation material.
Step 2, the high pressure cavity filling process that casting is shot using high-pressure casting visualization device；
Step 3, by CAE analysis result and actual photographed Comparative result, find out the principal element that influence CAE analysis fill type precision,
Amendment CAE analysis |input paramete, improves CAE analysis precision；Specially：Mold temperature and reality first in contrast CAE analysis
Mold temperature difference in production, if exceeding temperature difference threshold value, cooling parameter in adjustment CAE checks that mould Zhong Ge roads are cold
But whether the time is consistent with the cool time in actual production, if cool time is inconsistent, according to the cooling in actual production
Time complexity curve；If cool time beat is consistent, the heat transfer coefficient and actual heat transfer coefficient one in CAE databases are further ensured that
Cause；
If the mold temperature in CAE analysis is not above temperature difference threshold value, temperature with the mold temperature difference in actual production
The temperature range of discrepancy threshold is set to ± 10 DEG C, then contrast filling mould states in CAE, fill type order, the trend of bubble and slag inclusion,
Whether hyperbar position is consistent with actual photographed result；If consistent, continue checking for casting in threedimensional model and actual production,
The matching precision of mould, terminates comparison process；If inconsistent, the mold filling temperature and environment temperature set in CAE are checked, if with
Actual mold filling temperature is consistent with environment temperature, if not being inconsistent, temperature parameter is corrected, if being consistent, further combined with crystalline phase figure
And the molten metal temperature conditionss adjustment physical parameter such as viscosity coefficient and temperature-solidification rate curve；
After the threedimensional model of casting and material properties are changed each time, it is required for CAE analysis result and actual photographed result weight
New contrast, until the high pressure cavity filling process of CAE simulation casting is consistent with type situation is actually filled, the physical parameter that will be changed is preserved.
Concrete analysis example, high-pressure casting aluminium alloy cavity filling process is completed using simple casting die and visualization device,
Aluminum alloy materials are AlSi9Cu3, and pouring temperature is 700 DEG C, and filling velocity low speed 0.2m/s, high speed 2m/s obtain high-speed camera
Machine shoots and fills type view, as shown in Figure 3.CAE simulation softwards obtain analog result using MAGMA, as shown in Figure 2.
Find out from view is shot：Aluminium liquid shunted from running channel reach at first in the middle of ingate, now aluminium liquid start to the left and right two
Side is flowed, and into the ingate of both sides, and aluminium liquid is flowed into after casting reaches center by middle ingate and stopped always, directly
To aluminium liquid by the way that behind the center that left and right ingate also reaches casting, three bursts of aluminium liquids are flowed up simultaneously, until top, formed
Vortex stomata.
In the middle of example, the CAE analysis difference maximum with view is shot is that aluminium liquid reaches casting middle part by middle ingate
When do not stop, but flow all the way up, take the lead in reaching cast top.
The analysis of causes：Because the middle running channel of example casting is shorter in length than left and right sides running channel, aluminium liquid is at first by centre
Ingate, aluminium liquid is flowed up by middle ingate, when left and right sides aluminium liquid does not also pass through ingate, in the effect of gravity
Under, the flowing velocity of middle aluminium liquid is gradually reduced, and because example casting is thin-wall part, quickly, aluminium liquid generation is partially solidified for heat transfer,
Increase viscosity, and aluminium liquid in the running channel of the left and right sides now temperature is still higher, viscosity is small, and aluminium liquid is easier to be assigned to a left side
Right both sides pair running channel, stops, until aluminium always so as to aluminium liquid occur after middle ingate flows into casting arrival center
Liquid is by the way that behind the center that left and right ingate also reaches casting, three bursts of aluminium liquids are while the phenomenon for flowing up；But in CAE moulds
In plan it is this flowing solidification phenomenon do not embody in the calculation, need to correct again CAE simulation in aluminium alloy temperature-
Solidification rate data.
Slope increase by the temperature in CAE software database-solidification rate curve near eutectic line, that is to say, that with
The viscosity declined in this temperature province of temperature will be increased；Re-start CAE simulations and obtain analog result, as shown in figure 4,
Analog result display aluminium liquid passes through middle ingate and flows into casting, be stopped after reaching center, compares with actual result and connects
Closely.The temperature that this is corrected-solidification rate curve is applied to other intricate castings and then improves CAE and simulate fill type analysis precision.
Claims (3)
1. it is a kind of lifted high-pressure casting cavity filling process CAE analysis precision method, it is characterised in that concretely comprise the following steps：
Step one, the high pressure cavity filling process that casting is simulated with CAE software：The threedimensional model of casting is imported first in CAE software
And material properties；CAE analysis parameter is set further according to the technique in actual production, CAE simulations are carried out to high-pressure casting process；
Step 2, the high pressure cavity filling process that casting is shot using high-pressure casting visualization device；
Step 3, by CAE analysis result and actual photographed Comparative result, find out the principal element that influence CAE analysis fill type precision,
Amendment CAE analysis |input paramete, improves CAE analysis precision；Specially：Mold temperature and reality first in contrast CAE analysis
Mold temperature difference in production, if exceeding temperature difference threshold value, cooling parameter in adjustment CAE checks the cooling in mould
Whether the cool time that pipe is set is consistent with practical condition；If inconsistent, repaiied according to the cool time in actual production
Just；If cool time is consistent, further ensure that the heat transfer coefficient in CAE databases is consistent with actual heat transfer coefficient；
If the mold temperature in CAE analysis is not above temperature difference threshold value with the mold temperature difference in actual production, right
Than filling mould states in CAE, whether trend, the hyperbar position for filling type order, bubble and slag inclusion are consistent with actual photographed result；
If consistent, casting, the matching precision of mould in threedimensional model and actual production are continued checking for, terminate comparison process；If differing
Cause, check the mold filling temperature and environment temperature set in CAE, if be consistent with actual mold filling temperature and environment temperature, if not
Symbol, then correct temperature parameter, if being consistent, further combined with crystalline phase figure and molten metal temperature conditionss adjustment viscosity coefficient and temperature
The physical parameters such as degree-solidification rate curve；
After the threedimensional model of casting and material properties are changed each time, it is required for CAE analysis result and actual photographed result weight
New contrast, until the high pressure cavity filling process of CAE simulation casting is consistent with type situation is actually filled, the physical parameter that will be changed is preserved.
2. a kind of method for lifting high-pressure casting cavity filling process CAE analysis precision according to claim 1, its feature exists
In：The part and material of the material properties assignment include casting, mould, core, sprue cup, stalk, pressure chamber, drift, emit
Mouth, running channel, ingate, overflow launder, blast pipe, cooling tube, insulation material.
3. a kind of method for lifting high-pressure casting cavity filling process CAE analysis precision according to claim 1, its feature exists
In：The temperature range of temperature difference threshold value is set to ± 10 DEG C.
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Cited By (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN108335359A (en) * | 2018-01-23 | 2018-07-27 | 华中科技大学 | The method for tracing that oxide slag inclusion moves in a kind of Mold Filling Process |
| CN108994256A (en) * | 2018-08-17 | 2018-12-14 | 安徽合力股份有限公司合肥铸锻厂 | Casting production process based on 3D printing |
| CN110363759A (en) * | 2019-07-22 | 2019-10-22 | 国家超级计算天津中心 | Three-dimensional mould tuning parameter determines method and device |
| CN111014617A (en) * | 2019-12-13 | 2020-04-17 | 西安航天发动机有限公司 | Forming method of thin-wall volute casing with spiral structure based on antigravity casting |
| CN111581743A (en) * | 2020-04-30 | 2020-08-25 | 重庆长安汽车股份有限公司 | Defect risk assessment method based on casting simulation software |
| CN113295293A (en) * | 2021-04-12 | 2021-08-24 | 芜湖泓鹄材料技术有限公司 | Method for designing position of inner pouring gate of pouring system by detecting dynamic change of molten iron |
| CN113926865A (en) * | 2020-06-29 | 2022-01-14 | 宝山钢铁股份有限公司 | Casting blank slag inclusion forecasting method, machine cleaning control method, computing device and storage medium |
| CN115178723A (en) * | 2022-07-07 | 2022-10-14 | 苏州数算软云科技有限公司 | Method for calculating air pressure of mold in high-pressure casting process |
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Cited By (13)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN108335359A (en) * | 2018-01-23 | 2018-07-27 | 华中科技大学 | The method for tracing that oxide slag inclusion moves in a kind of Mold Filling Process |
| CN108994256A (en) * | 2018-08-17 | 2018-12-14 | 安徽合力股份有限公司合肥铸锻厂 | Casting production process based on 3D printing |
| CN110363759A (en) * | 2019-07-22 | 2019-10-22 | 国家超级计算天津中心 | Three-dimensional mould tuning parameter determines method and device |
| CN111014617A (en) * | 2019-12-13 | 2020-04-17 | 西安航天发动机有限公司 | Forming method of thin-wall volute casing with spiral structure based on antigravity casting |
| CN111014617B (en) * | 2019-12-13 | 2021-08-06 | 西安航天发动机有限公司 | Forming method of thin-wall volute casing with spiral structure based on antigravity casting |
| CN111581743A (en) * | 2020-04-30 | 2020-08-25 | 重庆长安汽车股份有限公司 | Defect risk assessment method based on casting simulation software |
| CN111581743B (en) * | 2020-04-30 | 2022-05-17 | 重庆长安汽车股份有限公司 | Defect risk assessment method based on casting simulation software |
| CN113926865B (en) * | 2020-06-29 | 2024-03-08 | 宝山钢铁股份有限公司 | Casting blank slag inclusion prediction method, machine cleaning control method, computing equipment and storage medium |
| CN113926865A (en) * | 2020-06-29 | 2022-01-14 | 宝山钢铁股份有限公司 | Casting blank slag inclusion forecasting method, machine cleaning control method, computing device and storage medium |
| CN113295293A (en) * | 2021-04-12 | 2021-08-24 | 芜湖泓鹄材料技术有限公司 | Method for designing position of inner pouring gate of pouring system by detecting dynamic change of molten iron |
| CN113295293B (en) * | 2021-04-12 | 2022-06-21 | 芜湖泓鹄材料技术有限公司 | Method for designing position of inner pouring gate of pouring system by detecting dynamic change of molten iron |
| CN115178723A (en) * | 2022-07-07 | 2022-10-14 | 苏州数算软云科技有限公司 | Method for calculating air pressure of mold in high-pressure casting process |
| CN115178723B (en) * | 2022-07-07 | 2024-08-23 | 苏州数算软云科技有限公司 | Calculation method of die air pressure in high-pressure casting process |
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