CN116776497A - Collaborative continuous simulation method for casting and heat treatment of cast steel large gear - Google Patents
Collaborative continuous simulation method for casting and heat treatment of cast steel large gear Download PDFInfo
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- CN116776497A CN116776497A CN202310775394.7A CN202310775394A CN116776497A CN 116776497 A CN116776497 A CN 116776497A CN 202310775394 A CN202310775394 A CN 202310775394A CN 116776497 A CN116776497 A CN 116776497A
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- 238000010438 heat treatment Methods 0.000 title claims abstract description 81
- 238000005266 casting Methods 0.000 title claims abstract description 63
- 238000004088 simulation Methods 0.000 title claims abstract description 52
- 229910001208 Crucible steel Inorganic materials 0.000 title claims abstract description 31
- 238000000034 method Methods 0.000 title claims abstract description 27
- 239000000463 material Substances 0.000 claims abstract description 25
- 238000007711 solidification Methods 0.000 claims abstract description 16
- 230000008023 solidification Effects 0.000 claims abstract description 16
- 239000004576 sand Substances 0.000 claims abstract description 14
- 230000000704 physical effect Effects 0.000 claims abstract description 12
- 238000006243 chemical reaction Methods 0.000 claims abstract description 4
- 238000005520 cutting process Methods 0.000 claims abstract description 4
- 238000003754 machining Methods 0.000 claims description 5
- 238000001816 cooling Methods 0.000 claims description 4
- 239000002826 coolant Substances 0.000 claims description 3
- 238000009864 tensile test Methods 0.000 claims description 3
- 238000009792 diffusion process Methods 0.000 claims description 2
- 238000004519 manufacturing process Methods 0.000 description 6
- 230000007547 defect Effects 0.000 description 3
- 230000005540 biological transmission Effects 0.000 description 2
- 238000000465 moulding Methods 0.000 description 2
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 239000004566 building material Substances 0.000 description 1
- 238000004364 calculation method Methods 0.000 description 1
- 238000010924 continuous production Methods 0.000 description 1
- 238000007599 discharging Methods 0.000 description 1
- 238000005272 metallurgy Methods 0.000 description 1
- 230000008520 organization Effects 0.000 description 1
- 238000007528 sand casting Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 230000009466 transformation Effects 0.000 description 1
- 239000002918 waste heat Substances 0.000 description 1
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- G06F2111/00—Details relating to CAD techniques
- G06F2111/02—CAD in a network environment, e.g. collaborative CAD or distributed simulation
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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
- G06F2119/08—Thermal analysis or thermal optimisation
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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
- G06F2119/14—Force analysis or force optimisation, e.g. static or dynamic forces
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Abstract
A collaborative continuous simulation method for casting and heat treatment of a cast steel large gear comprises the steps of firstly testing a casting material of the cast steel large gear to obtain a physical property parameter file; modeling by using three-dimensional modeling software to obtain a pre-cast gear model and a casting sand model, and performing grid subdivision by using grid software to obtain a casting grid file; inputting the physical property parameter file and the casting grid file into a thermal casting simulation software to perform casting and solidification simulation operation to obtain a solidification gear model and a casting simulation result file; cutting the solidified gear model through three-dimensional modeling software to obtain a heat treatment gear model, and carrying out grid subdivision through grid software to obtain a heat treatment grid file; clearing heat treatment invalid results in the casting simulation result file, and then performing user variable conversion on the rest heat treatment valid results to obtain a heat treatment initial condition file; and finally, performing heat treatment simulation operation through Simheat heat treatment simulation software to obtain a heat treatment simulation result file.
Description
Technical Field
The invention relates to the field of cast steel large gear simulation, in particular to a collaborative continuous simulation method for cast steel large gear casting and heat treatment.
Background
The cast steel large gear has better comprehensive mechanical property and formability, and is a key basic part of heavy equipment such as mines, metallurgy, building materials and the like. The diameter of the cast steel large gear can reach tens of meters at maximum, the weight of the cast steel large gear reaches hundred tons, the cast steel large gear mainly plays a role in power transmission and speed regulation, and the cast steel large gear has very high manufacturing requirements due to the characteristics of high transmission power, high rotating speed and the like.
The cast steel large gear molding process adopts a sand casting core assembly molding mode, and performance is optimized and adjusted through heat treatment after pit discharging. The cast steel large gear has large wall thickness difference, complex structure, multiple and dispersed heat joints and easy generation of defects such as shrinkage cavity shrinkage porosity, inclusions, cracks and the like, so that the requirements on technological parameters such as riser heads, chill, casting system design in a casting technological scheme, temperature, time, cooling mode and the like in a heat treatment technological scheme are very high in the production process. It is therefore particularly important to simulate the large gear prior to the actual production. From a casting standpoint, the solidification modeling software can predict most defects and their types and locations, such as shrinkage cavities, porosity, inclusions, cracks, stresses, deformations, and the like. From the heat treatment perspective, the heat treatment simulation software can predict the results of phase transformation, texture, deformation, hardness, etc.
However, the production process of the cast steel large gear is a continuous process from casting to heat treatment, the quality condition of the former process inevitably affects the latter process, that is, each process is not independent, but the prior art can only simulate the casting solidification process or the heat treatment process independently, and can not cooperate with the casting simulation result and the heat treatment simulation result, so that the limitation exists, and the accuracy of the final result after the heat treatment simulation can not be ensured.
Disclosure of Invention
The invention provides a collaborative continuous simulation method for casting and heat treatment of a cast steel large gear, which aims to solve the problem that only a casting solidification process or a heat treatment process can be independently simulated in the prior art.
The technical scheme adopted by the invention for solving the technical problems is as follows: a collaborative continuous simulation method for casting and heat treatment of a cast steel large gear comprises the following steps:
step one, testing a cast material of a cast steel large gear to obtain a thermal conductivity coefficient, a thermal expansion coefficient, a yield strength, a tensile strength, an elastic modulus, a material rheological stress curve, a TTT curve and a CCT curve of the cast material, and inputting the materials into a computer and storing the materials as physical property parameter files of the cast material;
modeling the cast steel large gear through three-dimensional modeling software to obtain a pre-cast gear model comprising a gear body, a chill and a riser bush, and extracting a casting cavity from a sand model through the pre-cast gear model to obtain a casting sand model; then, inputting the cast gear model and the cast sand mould model into grid software for grid subdivision to obtain a cast grid file;
inputting the physical property parameter file and the casting grid file into a thermal casting simulation software, setting casting boundary conditions in the thermal casting simulation software, and then performing casting and solidification simulation operation to obtain a solidification gear model and a casting simulation result file with a temperature field, a stress field and a component field;
cutting the solidified gear model through three-dimensional modeling software, and removing a riser and the machining quantity to obtain a heat treatment gear model; then inputting the heat treatment gear model into grid software for grid subdivision to obtain a heat treatment grid file;
step five, clearing heat treatment invalid results in the casting simulation result file, and then performing user variable conversion on the rest heat treatment valid results to obtain a heat treatment initial condition file;
inputting the heat treatment grid file, the heat treatment initial condition file, the TTT curve and the CCT curve into Simheat heat treatment simulation software, setting heat treatment boundary conditions in the Simheat treatment simulation software, and performing heat treatment simulation operation to obtain a heat treatment simulation result file.
Preferably, in the first step, the specific heat and the thermal diffusivity are measured by a laser thermal conductivity meter, and then the thermal conductivity is calculated; measuring the thermal expansion coefficient by a thermal expansion instrument; measuring yield strength, tensile strength and elastic modulus by a tensile testing machine; measuring a rheological stress curve of the material by a Gleeble thermal simulation tester; TTT curves and CCT curves are measured by a Formastor-F II phase change instrument.
Preferably, in the third step, the casting boundary conditions include heat exchange coefficient and sand mold physical property parameters.
Preferably, in step five, the heat treatment inefficiency results include equivalent strain, set time, and cooling rate.
Preferably, in step six, the heat treatment boundary conditions include furnace temperature, cooling medium and heat exchange coefficient.
According to the technical scheme, the invention has the beneficial effects that:
the invention carries out complete simulation on the whole process of casting the cast steel large gear from casting to solidification and pit discharge, and carries out heat treatment after machining, inherits the result which can affect the next process in each process, so that the continuous simulation collaborative continuous simulation of the whole process of casting and solidification and the heat treatment can be carried out, the accuracy of the final result after heat treatment simulation is ensured, the time and labor are saved, the reliability of the simulation result is higher, and the production cost can be effectively reduced.
Detailed Description
A collaborative continuous simulation method for casting and heat treatment of a cast steel large gear comprises the following steps:
step one, testing cast materials of cast steel large gears, measuring specific heat and thermal diffusion coefficients through a laser thermal conductivity meter, and then calculating the thermal conductivity coefficients; measuring the thermal expansion coefficient by a thermal expansion instrument; measuring yield strength, tensile strength and elastic modulus by a tensile testing machine; and measuring a rheological stress curve of the material by using a Gleeble thermal simulation tester, measuring a TTT curve and a CCT curve by using a Formastor-F II phase-change instrument, inputting the measuring results into a computer, and storing the measuring results as physical property parameter files of the casting material.
Modeling the cast steel large gear through three-dimensional modeling software to obtain a pre-cast gear model comprising a gear body, a chill and a riser bush, and extracting a casting cavity from a sand model through the pre-cast gear model to obtain a casting sand model; and then inputting the cast gear model and the cast sand model into grid software for grid subdivision to obtain a cast grid file.
Inputting the physical property parameter file and the casting grid file into a thermal casting simulation software, setting casting boundary conditions such as heat exchange coefficient, sand type physical property parameter and the like in the thermal casting simulation software, and then performing casting and solidification simulation operation to obtain a solidified gear model and a casting simulation result file with a temperature field, a stress field and a component field.
Cutting the solidified gear model through three-dimensional modeling software, and removing a riser and the machining quantity to obtain a heat treatment gear model; and then inputting the heat treatment gear model into grid software for grid subdivision to obtain a heat treatment grid file.
And fifthly, clearing heat treatment invalid results in the casting simulation result file, including equivalent strain, solidification time, cooling rate and the like, and then performing user variable conversion on the rest heat treatment valid results to obtain a heat treatment initial condition file.
Inputting the heat treatment grid file, the heat treatment initial condition file, the TTT curve and the CCT curve into Simheat heat treatment simulation software, setting heat treatment boundary conditions such as furnace temperature, cooling medium, heat exchange coefficient and the like in the Simheat treatment simulation software, and performing heat treatment simulation operation to obtain a heat treatment simulation result file.
Examples: taking a group of double-plate gears of a mill as an example, the diameter of the product to be simulated is 10 meters, the material is ZG40CrNi2Mo, the material belongs to an alloy cast steel material with high strength and toughness, and the chemical components and the weight ratio are as follows: c:0.43%, si:0.53%, mn:0.9%, S:0.003%, P:0.012%, cr:1.55%, ni:1.86%, mo:0.42%, nb:0.010%, al:0.033%, cu:0.10%, measuring specific heat and thermal diffusivity by using a laser thermal conductivity meter, and then calculating the thermal conductivity; measuring a TTT curve and a CCT curve by using a Formastor-F II phase change instrument; measuring a rheological stress curve of the material by using a Gleeble thermal simulation tester; the thermal expansion coefficient was measured using a thermal expansion instrument.
And then, presenting and processing the physical property parameter data of the material measured in the first step in an excel table form, writing a material file which can be identified by software, modeling the gear by using three-dimensional modeling software, drawing a gear body, a chill and a riser sleeve according to a process, and extracting a sand mold by using a cavity tool.
The model is imported into grid software, tetrahedral grids are drawn, grid refinement is carried out on positions with bad grid quality such as corners, a group of grid files with good grid quality are finally output, grid quality is checked in solidification simulation software, the minimum plane grid factor reaches 0.669, the minimum volume grid factor reaches 0.318, and the grid basic quality required by far-beyond software is achieved, so that the grid quality is good.
Setting up a solidification simulation engineering project, importing the model, importing a written material file, setting casting boundary conditions, performing operation calculation, and finally obtaining a casting simulation result file with results of a temperature field, a stress field, a component field and the like, and a solidification gear model.
And carrying out result processing on the casting simulation result file, loading heat treatment effective results such as temperature, deformation, stress, defects and the like, converting the heat treatment effective results into a data format which can be identified by heat treatment simulation software, resetting the invalid result of waste heat treatment, simultaneously removing riser heads and machining quantities of all surfaces of the solidified gear model to obtain the heat treatment gear model, inputting the heat treatment gear model into grid software for re-grid division, importing the generated TTT curve and CCT curve, setting heat treatment boundary conditions, and carrying out heat treatment simulation to obtain the heat treatment simulation result file such as organization, performance, deformation, hardness and the like.
According to the embodiment, the continuous simulation of the whole flow is carried out on the cast steel large gear, the result which can affect the next working procedure in each working procedure is inherited, time and labor are saved, the reliability of the final simulation result is higher, and the production cost can be effectively reduced.
Claims (5)
1. A collaborative continuous simulation method for casting and heat treatment of a cast steel large gear is characterized by comprising the following steps:
step one, testing a cast material of a cast steel large gear to obtain a thermal conductivity coefficient, a thermal expansion coefficient, a yield strength, a tensile strength, an elastic modulus, a material rheological stress curve, a TTT curve and a CCT curve of the cast material, and inputting the materials into a computer and storing the materials as physical property parameter files of the cast material;
modeling the cast steel large gear through three-dimensional modeling software to obtain a pre-cast gear model comprising a gear body, a chill and a riser bush, and extracting a casting cavity from a sand model through the pre-cast gear model to obtain a casting sand model; then, inputting the cast gear model and the cast sand mould model into grid software for grid subdivision to obtain a cast grid file;
inputting the physical property parameter file and the casting grid file into a thermal casting simulation software, setting casting boundary conditions in the thermal casting simulation software, and then performing casting and solidification simulation operation to obtain a solidification gear model and a casting simulation result file with a temperature field, a stress field and a component field;
cutting the solidified gear model through three-dimensional modeling software, and removing a riser and the machining quantity to obtain a heat treatment gear model; then inputting the heat treatment gear model into grid software for grid subdivision to obtain a heat treatment grid file;
step five, clearing heat treatment invalid results in the casting simulation result file, and then performing user variable conversion on the rest heat treatment valid results to obtain a heat treatment initial condition file;
inputting the heat treatment grid file, the heat treatment initial condition file, the TTT curve and the CCT curve into Simheat heat treatment simulation software, setting heat treatment boundary conditions in the Simheat treatment simulation software, and performing heat treatment simulation operation to obtain a heat treatment simulation result file.
2. The collaborative continuous simulation method for casting and heat treatment of the cast steel large gear according to claim 1, which is characterized in that: measuring specific heat and thermal diffusion coefficient by a laser thermal conductivity meter, and then calculating the thermal conductivity coefficient; measuring the thermal expansion coefficient by a thermal expansion instrument; measuring yield strength, tensile strength and elastic modulus by a tensile testing machine; measuring a rheological stress curve of the material by a Gleeble thermal simulation tester; TTT curves and CCT curves are measured by a Formastor-F II phase change instrument.
3. The collaborative continuous simulation method for casting and heat treatment of the cast steel large gear according to claim 1, which is characterized in that: in the third step, casting boundary conditions comprise heat exchange coefficient and sand mould physical property parameters.
4. The collaborative continuous simulation method for casting and heat treatment of the cast steel large gear according to claim 1, which is characterized in that: in step five, the invalid results of the heat treatment include equivalent strain, setting time and cooling rate.
5. The collaborative continuous simulation method for casting and heat treatment of the cast steel large gear according to claim 1, which is characterized in that: in the sixth step, the boundary conditions of the heat treatment comprise furnace temperature, cooling medium and heat exchange coefficient.
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| Application Number | Priority Date | Filing Date | Title |
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| CN202310775394.7A CN116776497A (en) | 2023-06-28 | 2023-06-28 | Collaborative continuous simulation method for casting and heat treatment of cast steel large gear |
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| CN202310775394.7A CN116776497A (en) | 2023-06-28 | 2023-06-28 | Collaborative continuous simulation method for casting and heat treatment of cast steel large gear |
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Effective date of registration: 20240306 Address after: 471000 No. 206, Jianxi, Luoyang District, Henan, Jianshe Road Applicant after: Luoyang Recasting Forging Co.,Ltd. Country or region after: China Applicant after: CITIC HEAVY INDUSTRIES Co.,Ltd. Applicant after: CITIC Corporation of China Address before: 471000 No. 206, Jianxi, Luoyang District, Henan, Jianshe Road Applicant before: Luoyang Recasting Forging Co.,Ltd. Country or region before: China Applicant before: CITIC HEAVY INDUSTRIES Co.,Ltd. |
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