铸造宏观过程数值模拟技术的研究现状与展望

doi:10.11900/0412.1961.2017.00317

金属学报

2018, Vol. 54

Issue (2): 161-173 DOI: 10.11900/0412.1961.2017.00317

本期目录 | 过刊浏览

铸造宏观过程数值模拟技术的研究现状与展望

廖敦明(

), 曹流, 孙飞, 陈涛

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

Research Status and Prospect on Numerical Simulation Technology of Casting Macroscopic Process

Dunming LIAO(

), Liu CAO, Fei SUN, Tao CHEN

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

引用本文:

廖敦明, 曹流, 孙飞, 陈涛. 铸造宏观过程数值模拟技术的研究现状与展望[J]. 金属学报, 2018, 54(2): 161-173.
Dunming LIAO, Liu CAO, Fei SUN, Tao CHEN. Research Status and Prospect on Numerical Simulation Technology of Casting Macroscopic Process[J]. Acta Metall Sin, 2018, 54(2): 161-173.

全文: PDF(4773 KB) HTML

摘要:

本文综述了铸造宏观过程模拟技术的研究现状。对比了不同流动场模型下铸造充型过程的差别,其中,两相流模型可准确地考虑气相对充型过程的影响。分析了不同应力场模型对铸造应力演变过程的适用程度,并阐明了其发展趋势。说明了适用于铸造宏观过程模拟的物性参数的获取及修正方法,即采用实验手段测量合金成分和液固相线温度,通过物性参数计算软件获得合金物性参数并做适当调整,进而结合测温实验对相关参数进行修正。对比了不同铸造工艺下的边界条件,并对高压铸造工艺(速度进口边界)和定向凝固工艺(辐射换热边界)的边界条件进行了说明。对比了不同网格类型的区别,并结合不同网格类型说明了不同数值求解算法的区别,本文认为自适应六面体网格和混合网格类型更适合于有限体积法(充型过程计算)和有限元法(凝固过程和应力计算)。针对各种铸造缺陷,对其预测模型和分析方法进行了说明,并阐明了其发展趋势。

关键词 ：铸造, 宏观过程, 数值模拟, 物理模型, 边界条件, 缺陷预测

Abstract：

In recent years, with increasingly maturing of computer simulation technology, numerical simulation methods are playing an increasing significant role in casting macroscopic process, and the research status on numerical simulation technologies in casting macroscopic processes is summarized in this paper. The differences in casting filling process discribed using different flow models are compared, and it is found that the two-phase flow model can be used to accurately handle the effect of gas phase on filling process. The applicabilities of different stress models to the evolution process of casting stress are also analyzed. The accessing and correcting method of physical property parameters, which is fit for simulation of casting macroscopic process, is explained. And the method is that the alloy composition and solidus/liquidus temperature are measured by experimental means, then physical property parameters are calculated by relevant softwares and adjusted accordingly, at last, the parameters are corrected according to temperature experiment. The boundary conditions of different casting techniques are listed, and, in addition, the boundary conditions of high pressure die casting (velocity inlet) and directional solidi fication (radiation heat transfer boundary) are explained specially. The differences of different mesh types are compared, in combination with which the differences of different numerical solution methods are analyzed. The suitable meshes would be adaptive hexahedral mesh and hybrid mesh, because they fit more for finite volume method (calculation for filling process) and finite element method (calculation for solidification and stress evolution processes). Prediction models and analysis methods of different casting defects are illustrated. In this paper, various methods used in simulation of casting process are introduced, and their application development trends are also predicted. We hope to offer a reliable reference for numerical simulation methods of casting macroscopic process.

Key words： casting macroscopic process numerical simulation mathematical model boundary condition defect prediction

收稿日期: 2017-07-26

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:

作者简介廖敦明,男,1973年生,教授

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https://www.ams.org.cn/CN/10.11900/0412.1961.2017.00317 或 https://www.ams.org.cn/CN/Y2018/V54/I2/161

图1 不同流动场模型下的充型过程模拟结果对比

图2 采用反热传导法求解铜合金与金属模具间的界面换热系数的实验设计和结果

图3 不同铸造工艺的模拟结果

表1 不同铸造工艺的边界条件

图4 不同的网格类型

图5 不同铸造缺陷的模拟结果

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