小型鑄鋼件多維振動鑄造機理研究
發(fā)布時間：2019-01-16 07:09
【摘要】：隨著汽車、鐵道車輛制造業(yè)的進步和我國鑄造行業(yè)準(zhǔn)入條件的推行,對整車的安全、高速、低耗、低成本及良好的舒適性等性能提出了較高要求。同時鑄鋼件型腔的復(fù)雜程度、壁厚、工藝精度等需求在不斷提高,給鑄鋼件鑄造工藝生產(chǎn)帶來較多的工藝和生產(chǎn)難題。本文以振動優(yōu)化列車車鉤縮松縮孔為主要研究目標(biāo),基于TRIZ和拓?fù)錂C構(gòu)設(shè)計理論設(shè)計制作了一臺多維振動鑄造機;利用EDEM-FLUENT液固兩相流耦合和基于相似準(zhǔn)則的物理模擬實驗,分別研究了多維振動物性參數(shù)對小型鑄鋼件車鉤試樣充型和縮松縮孔的影響。利用TRIZ對現(xiàn)有振動鑄造機系統(tǒng)功能、物質(zhì)-場及因果關(guān)系進行分析,理清其沖突、矛盾所在,根據(jù)拓?fù)浣Y(jié)構(gòu)理論在現(xiàn)有鑄造機基礎(chǔ)上提出一種振動物性參數(shù)獨立可調(diào)的多維振動鑄造機構(gòu)。利用ADAMS分析該多維運動機構(gòu)在不同工況下的運動性質(zhì),驗證振動在X、Y、Z方向的運動獨立性,證明此并聯(lián)機構(gòu)為完全解耦。借助EDEM-FLUENT固液兩相流耦合模擬分析小型鑄鋼件列車車鉤的試樣合金液在不同振動維數(shù)、振幅、振頻下對充型流動的影響,得出:在維數(shù)為XYZ、頻率為30Hz、振幅為0.35mm的振動條件下,鑄鋼液在螺旋試樣中的充型流動長度最佳�；谙嗨茰�(zhǔn)則和正交設(shè)計方式對小型鑄鋼件車鉤試樣進行實驗設(shè)計,通過物理模擬實驗研究多維振動參數(shù)對其縮松縮孔的影響,得出最優(yōu)振動參數(shù)為維數(shù)為XYZ、振頻35Hz、振幅0.30mm;并通過對各振動參數(shù)對縮松縮孔影響極差大小分析得出振動頻率影響最大,振動維數(shù)(自由度)次之,振動幅值影響相對較小。為進一步驗證多維振動鑄造技術(shù)對小型鑄鋼件缺陷的改善程度,以安徽鑫宏有限公司生產(chǎn)中某型號小型鑄鋼件列車車鉤為研究對象。通過ProCAST分析車鉤內(nèi)部所存在的縮松縮孔缺陷問題,并對原澆注方案存在的補縮不足問題進行優(yōu)化。并在優(yōu)化工藝基礎(chǔ)上對車鉤鑄件充型過程施加同EDEM-FLUENT耦合模擬得出最佳振動物性參數(shù);并對凝固過程施加物理模擬得出的最優(yōu)振動參數(shù)進行振動優(yōu)化。通過理論、數(shù)值模擬和實驗分析得出,小型鑄鋼件列車車鉤在振動參數(shù)為XYZ維數(shù)、30Hz頻率、0.35mm振幅下充型,在XYZ維數(shù)、35Hz頻率、0.30mm振幅凝固鑄件缺陷改善程度最佳。通過對試制車鉤樣件進行X射線無損檢測,檢測結(jié)果表明振動優(yōu)化后的車鉤鑄件縮松縮孔缺陷明顯減少,鑄件品質(zhì)得到很大提升,有效的為企業(yè)解決縮松縮孔缺陷問題。由理論、數(shù)值模擬和實驗分析得出,小型鑄鋼件列車車鉤在振動參數(shù)為XYZ維數(shù)、30Hz頻率、0.35mm振幅下充型,在XYZ維數(shù)、35Hz頻率、0.30mm振幅凝固鑄件缺陷改善程度最佳。
[Abstract]:With the progress of automobile and railway vehicle manufacturing industry and the implementation of the entry conditions of foundry industry in China, the safety, high speed, low consumption, low cost and good comfort of the whole vehicle are required. At the same time, the complex degree of casting cavity, wall thickness, process precision and other requirements are increasing, which brings more problems to the casting process production of steel castings. In this paper, a multi-dimensional vibration casting machine is designed and manufactured based on TRIZ and topological mechanism design theory, taking the vibration optimization of train couplers as the main research goal. By using EDEM-FLUENT liquid-solid two-phase flow coupling and physical simulation experiments based on similarity criterion, the effects of multi-dimension vibration animal parameters on filling mold and shrinkage hole of coupler specimen for small steel castings were studied. This paper analyzes the function, material field and causality of the existing vibratory casting machine system by using TRIZ, and clarifies the conflict and contradiction. Based on the topological structure theory, a multi-dimensional vibrating casting mechanism with independent and adjustable vibrational animal parameters is proposed on the basis of the existing foundry machines. The kinematic properties of the multi-dimensional kinematic mechanism under different working conditions are analyzed by using ADAMS. The kinematic independence of the vibration in the direction of XFY Z is verified. It is proved that the parallel mechanism is completely decoupled. With the aid of EDEM-FLUENT solid-liquid two-phase flow coupling simulation, the effects of the sample alloy liquid on the filling flow of couplers of small steel castings under different vibration dimensions, amplitudes and frequencies are analyzed. It is concluded that the dimension is 30 Hz at XYZ, frequency. When the vibration amplitude is 0.35mm, the filling length of molten steel in helical specimen is the best. Based on the similarity criterion and orthogonal design method, the experimental design of couplers for small steel castings was carried out. The effects of multi-dimensional vibration parameters on shrinkage and shrinkage of couplers were studied by physical simulation experiments, and the optimum vibration parameters were obtained as the dimension of XYZ, vibration frequency 35 Hz. Amplitude 0.30mm; The results show that the vibration frequency is the most important, the vibration dimension (degree of freedom) is the second, and the vibration amplitude is relatively small. In order to further verify the improvement degree of multi-dimensional vibration casting technology to the defect of small steel castings, a model of small steel castings train couplers produced by Anhui Xinhong Co., Ltd was taken as the research object. The defect of shrinkage hole in coupler was analyzed by ProCAST, and the problem of feeding deficiency in the original pouring scheme was optimized. On the basis of the optimized technology, the optimal vibrational animal parameters are obtained by applying the coupling simulation with EDEM-FLUENT to the filling process of the coupler casting, and the optimum vibration parameters obtained by the physical simulation of the solidification process are optimized. Through theoretical, numerical simulation and experimental analysis, it is concluded that the parameters of small cast steel train couplers are XYZ dimension, 30Hz frequency, 0.35mm amplitude filling, and the improvement degree of defects in solidified castings with XYZ dimension, 35Hz frequency and 0.30mm amplitude is the best. By means of X-ray nondestructive testing of the coupler sample, the results show that the shrinkage hole defects of the coupler castings after vibration optimization are obviously reduced, and the casting quality is greatly improved, which effectively solves the problem of shrinkage hole defects for enterprises. By theoretical, numerical simulation and experimental analysis, it is concluded that the parameters of small steel casting train coupler are XYZ dimension, 30Hz frequency, 0.35mm amplitude filling, and the best improvement degree is in XYZ dimension, 35Hz frequency, 0.30mm amplitude solidification casting defect.
【學(xué)位授予單位】：安徽理工大學(xué)
【學(xué)位級別】：碩士
【學(xué)位授予年份】：2017
【分類號】：TG260
本文編號：2409578
[Abstract]:With the progress of automobile and railway vehicle manufacturing industry and the implementation of the entry conditions of foundry industry in China, the safety, high speed, low consumption, low cost and good comfort of the whole vehicle are required. At the same time, the complex degree of casting cavity, wall thickness, process precision and other requirements are increasing, which brings more problems to the casting process production of steel castings. In this paper, a multi-dimensional vibration casting machine is designed and manufactured based on TRIZ and topological mechanism design theory, taking the vibration optimization of train couplers as the main research goal. By using EDEM-FLUENT liquid-solid two-phase flow coupling and physical simulation experiments based on similarity criterion, the effects of multi-dimension vibration animal parameters on filling mold and shrinkage hole of coupler specimen for small steel castings were studied. This paper analyzes the function, material field and causality of the existing vibratory casting machine system by using TRIZ, and clarifies the conflict and contradiction. Based on the topological structure theory, a multi-dimensional vibrating casting mechanism with independent and adjustable vibrational animal parameters is proposed on the basis of the existing foundry machines. The kinematic properties of the multi-dimensional kinematic mechanism under different working conditions are analyzed by using ADAMS. The kinematic independence of the vibration in the direction of XFY Z is verified. It is proved that the parallel mechanism is completely decoupled. With the aid of EDEM-FLUENT solid-liquid two-phase flow coupling simulation, the effects of the sample alloy liquid on the filling flow of couplers of small steel castings under different vibration dimensions, amplitudes and frequencies are analyzed. It is concluded that the dimension is 30 Hz at XYZ, frequency. When the vibration amplitude is 0.35mm, the filling length of molten steel in helical specimen is the best. Based on the similarity criterion and orthogonal design method, the experimental design of couplers for small steel castings was carried out. The effects of multi-dimensional vibration parameters on shrinkage and shrinkage of couplers were studied by physical simulation experiments, and the optimum vibration parameters were obtained as the dimension of XYZ, vibration frequency 35 Hz. Amplitude 0.30mm; The results show that the vibration frequency is the most important, the vibration dimension (degree of freedom) is the second, and the vibration amplitude is relatively small. In order to further verify the improvement degree of multi-dimensional vibration casting technology to the defect of small steel castings, a model of small steel castings train couplers produced by Anhui Xinhong Co., Ltd was taken as the research object. The defect of shrinkage hole in coupler was analyzed by ProCAST, and the problem of feeding deficiency in the original pouring scheme was optimized. On the basis of the optimized technology, the optimal vibrational animal parameters are obtained by applying the coupling simulation with EDEM-FLUENT to the filling process of the coupler casting, and the optimum vibration parameters obtained by the physical simulation of the solidification process are optimized. Through theoretical, numerical simulation and experimental analysis, it is concluded that the parameters of small cast steel train couplers are XYZ dimension, 30Hz frequency, 0.35mm amplitude filling, and the improvement degree of defects in solidified castings with XYZ dimension, 35Hz frequency and 0.30mm amplitude is the best. By means of X-ray nondestructive testing of the coupler sample, the results show that the shrinkage hole defects of the coupler castings after vibration optimization are obviously reduced, and the casting quality is greatly improved, which effectively solves the problem of shrinkage hole defects for enterprises. By theoretical, numerical simulation and experimental analysis, it is concluded that the parameters of small steel casting train coupler are XYZ dimension, 30Hz frequency, 0.35mm amplitude filling, and the best improvement degree is in XYZ dimension, 35Hz frequency, 0.30mm amplitude solidification casting defect.
【學(xué)位授予單位】：安徽理工大學(xué)
【學(xué)位級別】：碩士
【學(xué)位授予年份】：2017
【分類號】：TG260
【參考文獻】
相關(guān)期刊論文 前10條
1 康燕;毛衛(wèi)民;許杜生;陳藝駿;荊劍;程雪梅;;機械振動對熔模鑄造0Cr17不銹鋼組織與性能的影響[J];特種鑄造及有色合金;2015年10期
2 柳建國;徐偉東;;熔模鑄鋼件裂紋改善措施研究與應(yīng)用[J];金屬加工(熱加工);2015年07期
3 趙建華;馬強;金通;代雪佳;;機械振動對A356合金充型能力影響的研究[J];功能材料;2014年15期
4 王成軍;韓董董;陳蕾;蔣遠(yuǎn)遠(yuǎn);;振動技術(shù)在金屬材料鑄造成形中的應(yīng)用與發(fā)展[J];河北科技大學(xué)學(xué)報;2014年03期
5 趙建華;侯釗;王亞軍;;機械振動對AZ91鎂合金充型能力的影響[J];材料科學(xué)與工藝;2013年03期
6 肖海波;藍(lán)勇;;振動澆注在精密鑄造中的應(yīng)用[J];特種鑄造及有色合金;2013年05期
7 張潔;王剛;鄭福生;李峰;戴朋龍;;基于ProCast的高壓水泵殼熔模鑄造工藝研究[J];鑄造;2012年11期
8 唐寧;許慶彥;柳百成;;重型燃?xì)廨啓C葉片熔模鑄造過程數(shù)值模擬[J];特種鑄造及有色合金;2011年11期
9 黃真;劉婧芳;李艷文;;150年機構(gòu)自由度的通用公式問題[J];燕山大學(xué)學(xué)報;2011年01期
10 張慧杰;嚴(yán)峰;秦曉鋒;李志強;陶春國;覃作祥;陸興;;列車車鉤用ZG25MnCrNiMo鋼的沖擊性能研究[J];金屬熱處理;2010年07期
相關(guān)會議論文 前1條
1 王孜;;中國重型機械大型鑄鍛件行業(yè)現(xiàn)狀分析及“十一五”發(fā)展趨勢[A];首屆中國大型鑄鍛件制造技術(shù)發(fā)展論壇論文集[C];2006年
相關(guān)碩士學(xué)位論文 前8條
1 劉凱;復(fù)雜鑄鋼件變胞振動鑄造工藝及設(shè)備研究[D];安徽理工大學(xué);2016年
2 孔令光;機械振動對ZL205A低壓鑄造合金縮松的影響[D];哈爾濱工業(yè)大學(xué);2014年
3 張強強;基于DEM-CFD耦合的顆粒在水中沉降過程仿真分析[D];吉林大學(xué);2014年
4 心男;基于EDEM-FLUENT耦合的氣吹式排種器工作過程仿真分析[D];吉林大學(xué);2013年
5 馮均明;振動鑄造中型腔內(nèi)金屬液流動的數(shù)值模擬研究[D];廣州大學(xué);2013年
6 侯釗;機械振動對AZ91鎂合金充型及凝固的影響研究[D];重慶大學(xué);2013年
7 曾禮;機械振動對A356鋁合金充型及凝固的影響研究[D];重慶大學(xué);2012年
8 趙亮;鋁合金拐臂箱體鑄造工藝數(shù)值模擬[D];武漢理工大學(xué);2011年
，本文編號：2409578
本文鏈接：http://sikaile.net/kejilunwen/jiagonggongyi/2409578.html
最近更新
教材專著
