【摘要】：冒口設(shè)計(jì)常用方法主要有模數(shù)法、比例法、三次方程法等。以數(shù)值模擬技術(shù)為基礎(chǔ),結(jié)合仿真優(yōu)化方法是一種更加科學(xué)的冒口設(shè)計(jì)方式,并且是未來(lái)冒口的主流設(shè)計(jì)方法。以冒口為研究對(duì)象,以數(shù)值模擬軟件為基礎(chǔ),結(jié)合優(yōu)化算法進(jìn)行了冒口設(shè)計(jì)新方法的研究。這種方法是以金屬凝固理論、鑄件形成理論、傳熱學(xué)、流體力學(xué)等學(xué)科為基礎(chǔ),科學(xué)的鑄造工藝設(shè)計(jì)方法,研究處于初始階段。研究結(jié)果能夠?yàn)槊翱谧詣?dòng)化與集成化的新方法研究工作打下一定基礎(chǔ),擺脫冒口設(shè)計(jì)對(duì)經(jīng)驗(yàn)的依賴(lài)。對(duì)仿真優(yōu)化方法在冒口設(shè)計(jì)中的應(yīng)用進(jìn)行了研究。將模擬用于策略驗(yàn)證的優(yōu)化方法用于冒口設(shè)計(jì)。對(duì)冒口的候選策略逐一輸入仿真模型,采用枚舉的方法來(lái)對(duì)比每個(gè)策略的效果,完成冒口的設(shè)計(jì)。這種設(shè)計(jì)方法將仿真技術(shù)和優(yōu)化技術(shù)結(jié)合在一起,具有簡(jiǎn)單易行快速得到優(yōu)化結(jié)果的特點(diǎn),適用于規(guī)律性問(wèn)題的研究。在冒口形狀優(yōu)化的研究中應(yīng)用了這種方法。針對(duì)冒口優(yōu)化設(shè)計(jì)中多參數(shù)優(yōu)化效率低下、優(yōu)化過(guò)程復(fù)雜的問(wèn)題,對(duì)冒口形狀優(yōu)化進(jìn)行了基礎(chǔ)性的研究工作,確定具有最佳補(bǔ)縮效果的冒口形狀。詳細(xì)地給出了冒口高度、直徑對(duì)補(bǔ)縮效果的影響,將冒口的多參數(shù)優(yōu)化問(wèn)題轉(zhuǎn)化為以直徑為參考的單變量函數(shù)優(yōu)化問(wèn)題。對(duì)于冒口形狀優(yōu)化,研究了相同模數(shù)、不同形狀冒口的補(bǔ)縮能力。在冒口剛好完成對(duì)鑄件補(bǔ)縮的情況下,相同模數(shù)的球形冒口的補(bǔ)縮能力比等邊圓柱和正方體的補(bǔ)縮能力低。結(jié)果表明模數(shù)相同、由于形狀因素對(duì)冒口體積的影響,使冒口的補(bǔ)縮能力有很大的不同。研究了不同形狀冒口的補(bǔ)縮能力。分別用球形、等邊圓柱和正方體形狀冒口對(duì)相同鑄件進(jìn)行補(bǔ)縮,安全高度為零,通過(guò)模擬用于策略驗(yàn)證的優(yōu)化設(shè)計(jì)方法,得到球形、等邊圓柱、正方體的體積比為:1:1.08:1.0825。球形冒口的補(bǔ)縮能力最好,正方體形狀最差,但與等邊圓柱的差別并不大。說(shuō)明在具有相同公切球的情況下,不同形狀對(duì)冒口的補(bǔ)縮能力影響區(qū)別不大。但是球形冒口在制作工藝上比較麻煩,所以,生產(chǎn)中常用圓柱形冒口進(jìn)行補(bǔ)縮。針對(duì)生產(chǎn)中常用的圓柱形冒口,研究了冒口高度對(duì)補(bǔ)縮能力的影響。當(dāng)冒口的高徑比K≤0.7時(shí),隨著冒口高度的增加,縮孔向上移動(dòng)的速度逐漸降低。當(dāng)K1后,由于冒口頂部距離鑄件距離變大,冒口頂部對(duì)鑄件溫度場(chǎng)的影響變小,所以增加冒口高度,基本不能提高冒口的補(bǔ)縮能力。研究了冒口直徑對(duì)補(bǔ)縮能力的影響。在K≤1范圍內(nèi),隨著冒口直徑的增大,縮孔高度逐漸升高,增加冒口直徑比增加高度效果要好。在0.7K≤1范圍內(nèi),可以通過(guò)提高冒口高度或增大冒口直徑來(lái)對(duì)冒口的補(bǔ)縮效果進(jìn)行微調(diào)。研究了具有最佳補(bǔ)縮形狀的冒口高徑比。在冒口體積相同情況下,比較不同K值的冒口補(bǔ)縮效率。當(dāng)冒口高徑比0.4≤K≤0.7時(shí),冒口具有很好的補(bǔ)縮效率,當(dāng)K=0.7時(shí),冒口的補(bǔ)縮效果最好。取K=0.7為冒口的最佳高徑比,將冒口的多參數(shù)優(yōu)化轉(zhuǎn)化為以直徑為參考的單變量函數(shù)優(yōu)化問(wèn)題。將求冒口最小體積的優(yōu)化問(wèn)題轉(zhuǎn)變?yōu)榍竺翱谧钚≈睆降囊痪S搜索問(wèn)題后,冒口優(yōu)化設(shè)計(jì)過(guò)程變得簡(jiǎn)單且設(shè)計(jì)效率明顯提高。對(duì)單變量函數(shù)的優(yōu)化問(wèn)題進(jìn)行了研究。從單變量函數(shù)優(yōu)化的基本思想、搜索區(qū)間的確定、優(yōu)化問(wèn)題的解決方法等幾方面對(duì)單變量冒口優(yōu)化問(wèn)題進(jìn)行了研究。將二分法和爬山算法相結(jié)合,提出了“貪吃蛇算法”,并詳細(xì)給出了算法的求解數(shù)學(xué)模型優(yōu)化算法具有收斂速度快、計(jì)算精度高、結(jié)果穩(wěn)定的特點(diǎn)。隨著優(yōu)化次數(shù)增加,精度能夠進(jìn)一步提高,但是優(yōu)化效率明顯降低,所以?xún)?yōu)化過(guò)程中要選擇合適的優(yōu)化精度以提高優(yōu)化效率、減少優(yōu)化次數(shù)。采用這種方法,進(jìn)行了冒口優(yōu)化設(shè)計(jì)對(duì)比實(shí)驗(yàn),優(yōu)化過(guò)程從原來(lái)的110次減少到4次。結(jié)果表明將冒口的多參數(shù)優(yōu)化問(wèn)題轉(zhuǎn)變?yōu)閱巫兞亢瘮?shù)優(yōu)化后,冒口優(yōu)化設(shè)計(jì)過(guò)程變得簡(jiǎn)單且設(shè)計(jì)效率明顯提高。經(jīng)過(guò)分析后,找到了貪吃蛇算法存在的缺陷:搜索范圍為初始值加上2倍步長(zhǎng)。如果初始值過(guò)小,當(dāng)初始值小于目標(biāo)值的1/2時(shí),則導(dǎo)致不能得到優(yōu)化結(jié)果。為此,對(duì)冒口的優(yōu)化模型進(jìn)行修正,提出了向上翻倍長(zhǎng)大算法,并將長(zhǎng)大算法和優(yōu)化算法結(jié)合,建立了冒口“生長(zhǎng)”數(shù)學(xué)模型,實(shí)現(xiàn)了冒口的自動(dòng)化設(shè)計(jì)。這是一種全新的冒口設(shè)計(jì)方法,將冒口設(shè)計(jì)從靜態(tài)設(shè)計(jì)變成動(dòng)態(tài)生長(zhǎng)過(guò)程。在鑄件需要冒口的位置,放上冒口“種子”,在優(yōu)化迭代的過(guò)程中實(shí)現(xiàn)冒口的自然生長(zhǎng),最后“長(zhǎng)”到所需要的尺寸,完成冒口的設(shè)計(jì)。根據(jù)冒口“生長(zhǎng)”模型給出實(shí)例驗(yàn)證。這些研究為鑄造工藝設(shè)計(jì)的集成化和智能化打下了很好的基礎(chǔ),說(shuō)明了將數(shù)值模擬與仿真優(yōu)化技術(shù)相結(jié)合進(jìn)行冒口設(shè)計(jì)的新方法,具有強(qiáng)大的技術(shù)優(yōu)勢(shì)和非常廣闊的應(yīng)用前景。
[Abstract]:The common methods of riser design are modulus method, proportion method, cubic equation method, etc. Based on numerical simulation technology, combined with simulation optimization method is a more scientific riser design method, and is the mainstream design method of the future riser. This method is based on metal solidification theory, casting formation theory, heat transfer theory, fluid mechanics and other disciplines, scientific casting process design method, research is at the initial stage. The research results can lay a certain foundation for the new method research of riser automation and integration, get rid of riser design to warp. The application of simulation optimization method in riser design is studied. The optimization method for strategy validation is applied to riser design. The candidate riser strategies are input into the simulation model one by one, and the effect of each strategy is compared by enumeration method to complete riser design. This method is applied to the study of riser shape optimization. Aiming at the problems of low efficiency and complex optimization process of multi-parameter optimization in riser shape optimization design, the basic research on riser shape optimization is carried out. The influence of riser height and diameter on feeding effect is given in detail. The multi-parameter optimization problem of riser is transformed into a single variable function optimization problem with diameter as reference. For riser shape optimization, the feeding capacity of risers with the same modulus and different shapes is studied. The feeding capacity of spherical risers with the same modulus is lower than that of equilateral cylinders and cubes when the feeding of castings is just completed. By simulating the optimal design method for strategy validation, the spherical and equilateral cylinders are obtained. The volume ratio of the cube is 1:1.08:1.0825. The spherical riser has the best feeding capacity and the cube has the worst feeding capacity, but the difference between the spherical riser and the equilateral cylinder is not great. In the case of the same common-cut sphere, the different shapes have little effect on the feeding capacity of the riser. But the spherical riser is troublesome in the manufacturing process, so the cylindrical riser is often used in production. When the riser height is less than 0.7, the upward movement speed of the shrinkage hole decreases gradually with the increase of the riser height. When the distance between the riser top and the castings increases, the influence of the riser top on the temperature field of the castings decreases, so increasing the riser height can hardly improve the feeding capacity of the riser. In the circumference, with the increase of the riser diameter, the shrinkage height increases gradually, and the effect of increasing the riser diameter ratio is better than that of increasing the riser height. When the riser height-diameter ratio is 0.4 < K < 0.7, the riser has a good feeding efficiency. When K = 0.7, the feeding effect of the riser is the best. The optimization problem is transformed into a one-dimensional optimization problem for finding the minimum diameter of riser, and the optimization design process becomes simple and the design efficiency is improved obviously. Combining dichotomy with hill-climbing algorithm, a "snake-eating algorithm" is proposed, and the mathematical model optimization algorithm of the algorithm is given in detail, which has the characteristics of fast convergence, high precision and stable results. In the optimization process, the appropriate optimization precision should be selected to improve the optimization efficiency and reduce the number of optimization times. By using this method, the comparative experiment of riser optimization design is carried out, and the optimization process is reduced from 110 times to 4 times. After analysis, the shortcomings of the algorithm are found: the search range is the initial value plus two times the step size. If the initial value is too small, and the initial value is less than 1/2 of the target value, the optimization results can not be obtained. Therefore, the optimization model of the riser is modified and the upside doubling length is proposed. A new riser design method is proposed, which changes riser design from static design to dynamic growth process. In castings where risers are needed, a riser "seed" is placed and the iterative process is optimized. The natural growth of riser is realized, and finally the riser is "long" to the required size, and the riser design is completed. An example is given to verify the riser growth model. The method has strong technical advantages and very broad application prospects.
【學(xué)位授予單位】：沈陽(yáng)工業(yè)大學(xué)
【學(xué)位級(jí)別】：博士
【學(xué)位授予年份】：2015
【分類(lèi)號(hào)】：TG244.4

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