发动机缸体消失模模具CAD及射料过程的数值模拟-材料加工工程专业论文.docxVIP

摘 要 干砂负压消失模铸造技术中模样是消失模铸造成败的关键，而泡沫珠粒的充填 是获得优质泡沫模样的关键工序之一。在发动机缸体泡沫模样发泡成型时，泡沫珠 粒在模具中充填经常出现不均或不密实，导致模样出现残缺不全或融合不充分等缺 陷，影响产品的质量。利用计算机对泡沫珠粒射料充填过程的流动场进行数值模拟， 定量地了解射料过程的影响因素，有利于优化射料工艺、提高效率和减少废品。 本文利用 UG 软件对一复杂发动机缸体进行了优化分片，以有利于保证模样的精 度和后续的铸造工艺。从泡沫成型、方便制造等角度，完成了发泡模具结构的优化 设计，获得了完好的缸体模样。 本文针对发泡模具射料充填过程中复杂的气固两相流动，建立了基于欧拉-拉格 朗日模型的考虑可压缩性影响的密相气固两相流的模型，详细推导出该模型的表达 方程式，比较全面系统地推导出含有 6 个未知变量的密相可压气固两相流的封闭的 偏微分方程组，为流场的数值分析奠定了坚实的理论基础。 采用 C 语言编写程序，使用 SIMPLE 算法和隐式分离数值求解方法计算了已推 导的控制方程组的解，对泡沫颗粒充填过程的流体相进行二维数值模拟，并与实际 的物理模拟对比，结果表明与物理模拟的结果基本一致。 关键词：消失模铸造 发动机缸体 射料过程 欧拉-拉格朗日模型 数值模拟 Abstract The foam pattern is the key influential factor in lost foam casting process. The filling process is one of the crucial processes to ensure the high quality of the foam pattern. While obtaining the foam of engine cylinder filling without uniformity and denseness will cause various defects and affect the quality of the surface. The influence of parameter factors on filling process were realized by the numerical simulation of filling process. It is beneficial to optimize the filling process, enhance the efficiency and decrease the waster. In this paper, the slices of foam pattern for a complex engine cylinder were optimal designed which is beneficial to precision of the foam pattern and the following casting process. the foam mold was optimal designed in view of foam molding and convenient manufacturing. The whole foam was acquired. Aim at the complex gas-solid two-phase turbulent flow in filling process of lost foam casting, the Euler-Lagrange mathematics model for the dense gas-solid two-phase turbulent flow was set up which variable density is taken into account. The partial differential equations containing 6 variables were established systematically and the foundation is thus laid for numerical analysis. The simulation program was compiled with C language. The result of the control equations were computed with the SIMPLE arithmetic and the concealed separate numerical value method. The numerical simulation of