铸造充型过程中液固转变影响流动行为的数值计算

doi:10.11900/0412.1961.2017.00083

金属学报

2017, Vol. 53

Issue (11): 1521-1531 DOI: 10.11900/0412.1961.2017.00083

研究论文

本期目录 | 过刊浏览

铸造充型过程中液固转变影响流动行为的数值计算

曹流, 孙飞(

), 陈涛, 滕子浩, 唐玉龙, 廖敦明

华中科技大学材料成形及模具技术国家重点实验室武汉 430074

Numerical Simulation of Liquid-Solid Conversion Affecting Flow Behavior During Casting Filling Process

Liu CAO, Fei SUN(

), Tao CHEN, Zihao TENG, Yulong TANG, Dunming LIAO

State Key Laboratory of Materials Processing and Die & Mould Technology, Huazhong University of Science and Technology, Wuhan 430074, China

引用本文:

曹流, 孙飞, 陈涛, 滕子浩, 唐玉龙, 廖敦明. 铸造充型过程中液固转变影响流动行为的数值计算[J]. 金属学报, 2017, 53(11): 1521-1531.
Liu CAO, Fei SUN, Tao CHEN, Zihao TENG, Yulong TANG, Dunming LIAO. Numerical Simulation of Liquid-Solid Conversion Affecting Flow Behavior During Casting Filling Process[J]. Acta Metall Sin, 2017, 53(11): 1521-1531.

全文: PDF(6335 KB) HTML

摘要:

为准确预测浇不足及冷隔,在已有的处理液固转变方法基础上,提出基于固相率变化的糊状区流动行为计算模型,该模型可以有效地处理液固转变过程中糊状区不同阶段的流动行为,即高固相率糊状区采用临界固相率方法,低固相率糊状区采用变黏度方法,中等固相率糊状区采用多孔介质拖拽模型。模拟了S型铸型水模拟实验,模拟结果与实验结果吻合很好,验证了不考虑液固转变时所采用模型的准确性。针对简单形状的底注式铸造工艺,对比分析了处理液固转变过程中采用不同控制参数的计算效果,证明了糊状区流动行为计算模型的合理性。

关键词 ：液固转变, 糊状区, 多孔介质, 变黏度, 有限体积法, 数值模拟

Abstract：

Misrun and cold shut are common defects in casting productions, which could make surface accuracy of castings poorer, even leading to cracking and casting scraps in them. The formation process of misrun and cold shut is hard to be observed directly only by experiment measures, since casting filling process is in a state of high temperature flow inside mold. The key to predict the defects accurately is the way to handle the effect of liquid-solid conversion on flow behavior. On the basis of existing methods for treating liquid-solid conversion, a calculation model of mushy region flow behavior through measurement of solid-fraction is developed, which can effectively investigate the flow behavior of mushy region in different stages. Generally, the critical solid-fraction method is adopted for mushy region with high solid-fraction, in consideration of that only the speed of high solid-fraction region is supposed to be zero during casting filling process. The variable viscosity method is applied for mushy region with low solid-fraction, due to casting filling process being unlikely to form toothpaste-like flow. However, the porous medium drag-based model is used for mushy region with middle solid-fraction, because only the middle solid-fraction region can be equivalent to porous medium. Combining the above three methods, a flow-field calculation program considering the effect of liquid-solid conversion on flow behavior during casting filling process is developed, in which finite volume method (FVM) is included for discretization equations; the pressure implicit with splitting of operator (PISO) algorithm is added for coupling pressure and velocity; the volume of fluid (VOF) algorithm is also combined for interface tracking. An numerical simulation of water-filled S-shaped channel is performed in the case of taking no account of liquid-solid conversion, and the simulated results coincide better with the experimental results, which certifies for its accuracy as an adopted model. Since the bottom filling casting craft is commonly used in single-shape casting, a comparison between the calculated results obtained using other single models and those using this model at different control parameters, is needed. The better agreement between them indicates that this new model is appropriate for calculating the flow behavior in mushy region.

Key words： liquid-solid conversion mushy region porous medium variable viscosity finite volume method numerical simulation

收稿日期: 2017-03-15

ZTFLH:

TG245

基金资助:教育部新世纪优秀人才支持计划项目No.NCET-13-0229和国家数控重大专项项目No.2012ZX04010-031

作者简介:

作者简介曹流,男,1991年生,博士生

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链接本文:

https://www.ams.org.cn/CN/10.11900/0412.1961.2017.00083 或 https://www.ams.org.cn/CN/Y2017/V53/I11/1521

图1 流动液相中树枝晶形貌演变过程示意图

图2 计算流程图

Parameter	Value	Unit
Water density	1000	kgm^-3
Air density	1	kgm^-3
Water dynamic viscosity	1×10^-3	Pas
Air dynamic viscosity	1×10^-5	Pas
Water-air surface tension coefficient	0.07275	Nm^-1
Acceleration of gravity	${0, 0, - 9.8}$	ms^-2
Inlet velocity	${0, 8.7, 0}$	ms^-1
Outlet pressure	0	Pa

表1 计算过程中所需设置的参数

图3 S型铸型水模拟实验与水的体积比和气液两相速度的模拟结果的对比

图4 底注式铸造工艺的几何及网格模型

Parameter	Value	Unit
Aluminum alloy density	2385	kgm^-3
Air density	1	kgm^-3
Aluminum alloy dynamic viscosity	0.003	Pas
Air dynamic viscosity	1×10^-5	Pas
Aluminum alloy-air surface tension coefficient	0.871	Nm^-1
Acceleration of gravity	${0, 0, - 9.8}$	ms^-2
Inlet velocity	${0, 0, 0.1}$	ms^-1
Outlet pressure	0	Pa
Liquidus temperature of aluminum alloy	660	℃
Solidus temperature of aluminum alloy	560	℃
Latent heat of aluminum alloy	300	Jg^-1
Inlet temperature	670	℃
Mold temperature	30	℃
Heat transfer coefficient between lower surface and mold	6000	Wm^-2K^-1
Heat transfer coefficient between other surfaces and mold	100	Wm^-2K^-1

表2 模拟计算过程中所设参数

图5 计算第5 s时不同临界固相率下铝相固相率、气液两相速度和铝相体积比的模拟结果对比

图6 计算第5 s时不同固相黏度下铝相固相率、气液两相速度和铝相体积比的模拟结果对比

图7 计算第5 s时不同多孔介质拖拽系数下铝相固相率、气液两相速度和铝相体积比的模拟结果对比

图8 采用基于固相率变化的糊状区流动行为计算模型时不同时刻的铝相固相率、气液两相速度和铝相体积比的模拟结果

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