【摘要】：為了適應(yīng)當(dāng)今工業(yè)朝著高、精、尖方向發(fā)展的需要,機(jī)床作為工業(yè)之母在這一進(jìn)程中扮演著舉足輕重的角色。立柱作為大型高檔數(shù)控機(jī)床的主要部件之一,立柱鑄件生產(chǎn)質(zhì)量的優(yōu)良與否與數(shù)控機(jī)床的工作壽命及其加工對(duì)象的精度高低是息息相關(guān)的。隨著工業(yè)產(chǎn)品對(duì)零件加工精度的要求日趨嚴(yán)苛,大型高檔數(shù)控機(jī)床對(duì)于立柱部件的剛度、抗偏載能力以及定位精度等各方面性能也提出了更高的要求。因此,要保證立柱具有足夠的強(qiáng)度和加工精度,就要求在立柱的鑄造過程中防止鑄造缺陷的產(chǎn)生。傳統(tǒng)的鑄造方法一般都是依靠經(jīng)驗(yàn)積累來進(jìn)行工藝設(shè)計(jì),這樣不僅容易造成材料的極大浪費(fèi)而且很難保證產(chǎn)品的質(zhì)量。本文以27系列龍門鏜銑床立柱為研究對(duì)象,采用PROCAST數(shù)值模擬仿真軟件對(duì)立柱的鑄造過程進(jìn)行數(shù)值模擬研究,并且根據(jù)企業(yè)的生產(chǎn)條件設(shè)計(jì)、改進(jìn)了生產(chǎn)工藝,減少了鑄造缺陷的產(chǎn)生。本文首先根據(jù)“臥澆底注”澆注理論對(duì)立柱的澆注系統(tǒng)進(jìn)行了設(shè)計(jì),并通過Proe5.0建立了初始方案的三維模型,然后在有限元鑄造工藝數(shù)值模擬系統(tǒng)PROCAST中對(duì)立柱的鑄造過程進(jìn)行數(shù)值模擬。通過分析立柱充型過程的溫度場(chǎng)與速度場(chǎng)變化以及凝固傳熱過程的溫度場(chǎng)變化,最終對(duì)鑄件可能會(huì)產(chǎn)生的各種鑄造缺陷進(jìn)行了可靠的模擬預(yù)測(cè)。本文通過對(duì)模擬結(jié)果進(jìn)行分析,討論了澆道對(duì)鐵水充型流速的影響以及鑄件凝固速度對(duì)鑄件缺陷的影響;通過多次試驗(yàn)后對(duì)初始方案進(jìn)行了改進(jìn),確定了比較合理的進(jìn)水方式以及冷鐵、通氣冒口的分布方式;通過有限差分模擬軟件Anycasting對(duì)改進(jìn)方案進(jìn)行了驗(yàn)證,兩種軟件對(duì)鑄件缺陷的預(yù)測(cè)具有較好的一致性。最后采用與仿真實(shí)驗(yàn)完全相同的鑄造工藝制作了實(shí)驗(yàn)件對(duì)改進(jìn)工藝進(jìn)行了驗(yàn)證,實(shí)驗(yàn)結(jié)果有力驗(yàn)證了模擬仿真分析結(jié)果的可靠性。通過數(shù)值模擬仿真軟件對(duì)鑄件的鑄造工藝進(jìn)行設(shè)計(jì)可以快捷直觀地觀察到該工藝生產(chǎn)質(zhì)量的好壞,以便工程師隨時(shí)對(duì)工藝進(jìn)行調(diào)整。這樣不僅可以縮短設(shè)計(jì)時(shí)間周期,還可以幫助企業(yè)在降低物料成本的前提下提高鑄件的良品率,對(duì)于企業(yè)生產(chǎn)復(fù)雜大型鑄件具有很好的指導(dǎo)意義。
[Abstract]:In order to adapt to the development of industry in the direction of high, fine and sharp, machine tools play a pivotal role in this process as the mother of industry. As one of the main components of large and high-grade NC machine tools, the quality of pillar castings is closely related to the working life of NC machine tools and the precision of machining objects. With the increasingly stringent requirements of industrial products for parts processing accuracy, large high-grade CNC machine tools have put forward higher requirements for the stiffness, offset resistance and positioning accuracy of column components. Therefore, to ensure that the column has sufficient strength and machining precision, it is necessary to prevent casting defects in the casting process. The traditional casting methods usually rely on the experience accumulation to carry out the process design, which is not only easy to cause great waste of materials, but also difficult to guarantee the quality of the products. This paper takes the column of 27 series gantry boring and milling machine as the research object, uses the PROCAST numerical simulation software to carry on the numerical simulation research to the vertical column casting process, and according to the enterprise production condition design, has improved the production craft, The production of casting defects is reduced. In this paper, the pouring system of the column is designed according to the theory of "horizontal bottom pouring", and the 3D model of the initial scheme is established by Proe5.0. Then the casting process of column is numerically simulated in the finite element casting process simulation system (PROCAST). By analyzing the change of temperature field and velocity field in the filling process of column and the change of temperature field in solidification and heat transfer process, a reliable simulation and prediction of various casting defects may be made. Through the analysis of the simulation results, the influence of the sprue on the filling velocity of the hot metal and the effect of the casting solidification rate on the casting defects are discussed, and the initial scheme is improved after many experiments. The reasonable influent mode and the distribution mode of cold iron and air riser are determined, and the improved scheme is verified by finite difference simulation software Anycasting. The two kinds of software have good consistency in predicting casting defects. Finally, the improved process is verified by using the same casting process as the simulation experiment, and the result of the experiment can verify the reliability of the simulation analysis result. The casting process can be designed by numerical simulation software, and the quality of the casting process can be observed quickly and intuitively, so that the engineer can adjust the process at any time. This can not only shorten the design time cycle, but also help enterprises to improve the quality of castings on the premise of reducing the cost of materials. It has a good guiding significance for enterprises to produce complex large castings.
【學(xué)位授予單位】：昆明理工大學(xué)
【學(xué)位級(jí)別】：碩士
【學(xué)位授予年份】：2017
【分類號(hào)】：TG24

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