熔模铸件尺寸控制的数字孪生建模关键技术与应用

doi:10.11900/0412.1961.2022.00263

金属学报

2024, Vol. 60

Issue (4): 548-558 DOI: 10.11900/0412.1961.2022.00263

研究论文

本期目录 | 过刊浏览

熔模铸件尺寸控制的数字孪生建模关键技术与应用

官邦¹, 汪东红¹^,²(

), 马洪波³, 疏达¹^,²(

), 丁正一¹, 崔加裕¹, 孙宝德¹^,²

1 上海交通大学材料科学与工程学院上海市先进高温材料及其精密成形重点实验室上海 200240
2 上海交通大学金属基复合材料国家重点实验室上海 200240
3 西安电子科技大学机电工程学院西安 710126

Key Technology and Application of Digital Twin Modeling for Deformation Control of Investment Casting

GUAN Bang¹, WANG Donghong¹^,²(

), MA Hongbo³, SHU Da¹^,²(

), DING Zhengyi¹, CUI Jiayu¹, SUN Baode¹^,²

1 Shanghai Key Lab of Advanced High-Temperature Materials and Precision Forming, School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai 200240, China
2 State Key Lab of Metal Matrix Composites, Shanghai Jiao Tong University, Shanghai 200240, China
3 School of Electro-Mechanical Engineering, Xidian University, Xi'an 710126, China

引用本文:

官邦, 汪东红, 马洪波, 疏达, 丁正一, 崔加裕, 孙宝德. 熔模铸件尺寸控制的数字孪生建模关键技术与应用[J]. 金属学报, 2024, 60(4): 548-558.
Bang GUAN, Donghong WANG, Hongbo MA, Da SHU, Zhengyi DING, Jiayu CUI, Baode SUN. Key Technology and Application of Digital Twin Modeling for Deformation Control of Investment Casting[J]. Acta Metall Sin, 2024, 60(4): 548-558.

全文: PDF(2811 KB) HTML

摘要:

熔模铸造工艺流程长、工序多，铸件成型过程孤岛控制，存在尺寸超差问题。本工作基于节点法向量和最近邻点，提出熔模铸造工艺全节点位移传递的计算方法，解决熔模铸件成型多流程的数据孤岛问题。研究蜡模注射成型和铸件凝固过程工艺参数-尺寸偏差的关系，为数字孪生建模提供数据模型。对环套环特征件建立铸件模具反变形设计和铸件多流程下工艺优化的数字孪生应用。该数字孪生模型应用于设计阶段，反变形设计出模具内腔的三维几何模型。模拟结果表明，铸件所有节点位移偏差在0.04 mm以下。应用于流程之间的工艺控制，根据前一工序下尺寸偏差，进行后续工艺优化调控。

关键词 ：熔模铸造, 尺寸传递, 反变形设计, 数字孪生, 智能铸造

Abstract：

Investment casting processes are controlled separately for its complex casting system, resulting in the dimensional out of tolerance. A calculation method for node displacement transfer is proposed based on the node normal vector and the nearest neighbor points in investment casting; the relationship between injection parameters, dimensional deviation in injected wax pattern, and casting solidification is studied, which provides a data model for digital twin. The digital twin is applied to the antideformation design and process optimization under a multiprocess for ring-to-ring casting. In the design stage, the geometric model of the mold cavity is designed via reverse deformation, and the error between the simulation results of the casting after the antideformation design and the target geometric is < 0.04 mm. In the casting, the optimal control of the subsequent process is performed according to the dimensional deviation of the previous process.

Key words： investment casting dimension transfer antideformation design digital twin intelligent casting

收稿日期: 2022-05-31

ZTFLH:

TG146.3

基金资助:国家重点研发计划项目(2022YFB3706800);国家重点研发计划项目(2020YFB1710100);国家科技重大专项项目(2017-Ⅶ-0008-0102);国家科技重大专项项目(J2019-VI-0004-0117);国家自然科学基金项目(51821001);国家自然科学基金项目(52090042);浙江省重点研发计划项目(2020C01056);浙江省重点研发计划项目(2021C01157);浙江省重点研发计划项目(2022C01147)

通讯作者: 汪东红，wangdh2009@sjtu.edu.cn，主要从事数字化智能化精密铸造研究;
疏达，dshu@sjtu.edu.cn，主要从事液态金属加工研究

Corresponding author: WANG Donghong, associate professor, Tel:(021)54748974, E-mail: wangdh2009@sjtu.edu.cn;
SHU Da, professor, Tel: (021)54748974, E-mail: dshu@sjtu.edu.cn

作者简介: 官邦，男，1995年生，博士生

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图1 铸件尺寸控制数字孪生建模仿真基本框架

图2 节点位移偏差计算示意图

图3 1 mm网格划分节点距离误差

表1 设计变量及其区间

图4 铸件几何模型

图5 蜡模变形和铸件变形模拟结果

图6 位移场和统计分布直方图表示位移的传递过程

图7 内环所有节点

图8 蜡模和铸件不同高度的尺寸偏差

图9 基于几何迭代反变形设计的铸件总位移分布

图10 铸件与蜡模之间不同高度的尺寸偏差

图11 CAD模型、蜡模和铸件的点云

图12 不同几何模型之间节点位移场云图和统计分布直方图

图13 Y方向和Z方向平均位移向量分量随叶片截面高度的变化曲线

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