回转台铸件铸造工艺及有限元数值模拟研究

发布时间：2018-05-09 17:02

本文选题：回转台 + ProCAST　；参考：《辽宁工程技术大学》2015年硕士论文

【摘要】：掘进机是用于开掘地下巷道的大型设备,悬臂式掘进机是煤矿采煤不可缺少的重要设备之一。回转台是掘进机的主要结构件,是本体与截割部的关键连接部件。通过回转台及回转支撑、回转油缸、支撑油缸的作用,截割部可以完成上下左右的多方向运动。回转台承受着截割部的多方向截割阻力作用,其可靠性和稳定性也直接关系到整机的使用寿命,因此,铸造回转台的内部质量非常重要。由于回转台是整体铸造,铸造质量合格率低,为了提前设定合理的铸造方式引进了数值模拟技术。利用计算机数值模拟铸造工艺的充型、凝固及缺陷产生趋向的过程,提前预测铸件各部位产生缺陷的情况,进而判断铸造工艺方案是否合理以及铸件结构是否需要改进,以满足技术要求。同时,以模拟依据进行铸造工艺和铸件结构的优化,降低或消除铸件内部缺陷,保证产品质量稳定,以降低制造成本,提升生产效率。本论文以EBZ16型回转台为例,根据铸件的结构特点及壁厚情况,在浇冒口系统的设计中,将内浇口数量定为4个和6个,冒口数量分别设为6个和8个。在同一工艺基础上,分别对四种浇铸系统下的回转台应用ProCAST软件进行充填凝固数值模拟。通过对结果分析,发现冒口数为6,浇道也为6时,铸件充型最平稳,金属液流动性好,获得的铸件缩松、缩孔面积也最小。实际中,对8冒口6浇道及6冒口6浇道两种方案进行试制,对浇注出的回转台铸件超声波探伤后,也验证出6冒口6浇道浇注出的铸件缺陷更少。
[Abstract]:Roadheader is a large equipment used to dig underground roadway, and cantilever roadheader is one of the most important equipment in coal mining. The turntable is the main structure of the roadheader and the key connecting part between the body and the cutting part. By means of rotary table and rotary support, rotary oil cylinder and supporting oil cylinder, the cutting part can accomplish multi-direction motion of the upper and lower parts. The rotary table bears the effect of multi-direction cutting resistance of cutting part, and its reliability and stability are also directly related to the service life of the whole machine. Therefore, the internal quality of the casting rotary table is very important. Because the turntable is integral casting and the qualified rate of casting quality is low, numerical simulation technology is introduced in order to set reasonable casting mode in advance. The process of mold filling, solidification and defect tendency of casting process is simulated by computer numerical simulation, and the defects in various parts of casting are predicted ahead of time, and then whether the casting process scheme is reasonable or not and whether the casting structure needs to be improved or not is judged. To meet technical requirements. At the same time, on the basis of simulation, the casting process and the casting structure are optimized to reduce or eliminate the internal defects of the casting, to ensure the stability of the product quality, to reduce the manufacturing cost and to improve the production efficiency. Taking EBZ16 type rotary table as an example, according to the structural characteristics and wall thickness of castings, in the design of riser system, the number of inner gate and riser are 4 and 6 respectively, and the number of risers are 6 and 8, respectively. On the basis of the same technology, the filling solidification numerical simulation of the rotary table under four kinds of casting systems was carried out by using ProCAST software. Through the analysis of the results, it is found that the riser number is 6 and the sprue is 6, the mold filling is the most stable, the liquid metal fluidity is good, the casting shrinkage is obtained, and the shrinkage area is also the smallest. In practice, two schemes of 8 risers, 6 sprue and 6 risers 6 sprue are trial-produced, and the defects of 6 riser 6 sprue castings are also verified after ultrasonic inspection of the castings.
【学位授予单位】：辽宁工程技术大学
【学位级别】：硕士
【学位授予年份】：2015
【分类号】：TD421.5;TG24

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