板类件冒口优化与缺陷判据的模拟研究

发布时间：2018-12-13 20:35

【摘要】：各类铸件上往往有很多板状结构。板类件的铸造缺陷是影响板类件铸件生产质量的主要因素,而消除缺陷的主要方法就是施加冒口,但是冒口大小、位置设计的不合理会导致铸件产生缺陷或者严重降低工艺出品率。因此本文对板类件冒口的设计方法和缺陷预测进行着重研究。基于ProCAST铸造工艺模拟软件研究冒口的生长算法,并利用贪吃蛇算法的快速优化过程,对板类铸件冒口设计进行了优化,并与传统的模数法进行了比较。根据不同板件厚度的模拟结果,发现板件经过5到6次计算,可获得最优解,同时冒口体积相对于模数法减小46%以上,工艺出品率则提高了20%左右。根据不同板件厚度的模拟结果,板件体积VC与生长算法设计冒口体积VR之间的关系为VC=(2.4~2.6)VR。根据40mm厚的板件浇铸试验,生长算法设计的冒口在满足铸件不存在缩孔缺陷的铸造要求下,冒口的体积为模数法的48%,工艺出品率可提高22%,同时凝固时间缩短550s。本文对Niyama判据和模数法的关联进行研究,利用模数对Niyama判据进行解释,得到了Niyama-模数法判据,并利用Niyama-模数法判据预测冒口直径为105mm的板件的缺陷。根据实际浇注试验的结果,在Niyama-模数法预测产生缺陷部位产生了铸造缺陷。通过沈阳某公司实际生产的铲板槽钢利用生长算法和Niyama-模数法判据设计冒口并预测缺陷。根据该公司实际生产的铸件,并经过X光探伤内部不存在缺陷,并且工艺出品率提高了12%左右,达到设计要求,因此证明生长算法和Niyama-模数法判据在实际生产中具有实用性。
[Abstract]:Various kinds of castings often have a lot of plate-like structure. The casting defects of plate parts are the main factors affecting the quality of plate castings, and the main way to eliminate the defects is to apply risers, but the size of risers, Unreasonable position design may lead to defects in the casting or seriously reduce the production rate of the process. Therefore, this paper focuses on the design method and defect prediction of risers for plate parts. This paper studies the riser growth algorithm based on ProCAST casting process simulation software, and optimizes the riser design of plate castings by using the fast optimization process of greedy snake algorithm, and compares it with the traditional modulus method. According to the simulation results of different thickness of plates, it is found that the optimal solution can be obtained after 5 to 6 calculations, and the riser volume is reduced by more than 46% compared with the modular method, and the yield of the process is increased by about 20%. According to the simulation results of different plate thickness, the relation between the plate volume VC and the riser volume VR of the growth algorithm is VC= (2.4 ~ 2.6) VR.. According to the casting test of 40mm thick sheet, the riser designed by the growth algorithm can meet the casting requirements without shrinkage defects, the volume of riser is 48 parts of that of modular method, the production rate of the process can be increased by 22 and the solidification time can be shortened by 550 s. In this paper, the correlation between Niyama criterion and modulus method is studied, the Niyama criterion is interpreted by modulus, and the Niyama- modulus criterion is obtained, and the Niyama- modulus method is used to predict the defects of the riser with 105mm diameter. According to the results of actual casting test, casting defects were predicted by Niyama- modulus method. By using the growth algorithm and Niyama- modulus criterion, the riser was designed and the defects were predicted by a shovel plate channel steel actually produced by a certain company in Shenyang. According to the actual castings produced by the company, there are no defects in the castings after X-ray inspection, and the production rate of the process has been increased by about 12% to meet the design requirements. Therefore, it is proved that the growth algorithm and the criterion of Niyama- modulus method are practical in practical production.
【学位授予单位】：沈阳工业大学
【学位级别】：硕士
【学位授予年份】：2017
【分类号】：TG244.4

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