大型机床床身铸造过程模拟仿真及工艺优化-材料加工工程专业论文.docx

山东理 山东理工大学硕士学位论文 摘 要 万方数据 万方数据 摘 要 本文主要研究内容是大型机床铸造过程的数值模拟仿真及工艺优化。计算机数值 模拟作为新兴产业已经越来越多的被铸造企业接受并应用，一般企业主要针对中小铸 件进行模拟仿真，但对于大型机床铸件的数值模拟经验极少，大型机床铸造过程的数 值模拟仿真及工艺优化对于凭经验浇注为主的大型铸件铸造具有科学理论指导意义。 本文利用 Anycasting 数值仿真模拟软件，针对大型机床床身铸造充型和凝固过程 进行数值模拟研究。首先，数值模拟基础是床身的三维实体造型，设计出造型后，将 造型导入 Anycasting 软件中，利用软件的网格划分功能对床身进行有限差分网格的划 分，完成铸造分析模型。然后确定铸造工艺参数，进行浇注试验，对铸件充型、凝固 过程进行数据模拟和研究，分析充型及凝固过程流场和温度场变化，并对缺陷进行预 测和分析。其次，采用单因素多水平实验法对浇注温度、流速、冷铁和涂料对铸件质 量的影响进行了研究，通过实验对比得出了合理的工艺参数，即注温度定位 1400℃， 流速定为 180cm/s。涂料和冷铁对大型机床床身铸造成型过程影响较大，对于大型机 床铸件，冷铁影响铸件的凝固顺序，型腔和型芯整体添加涂料会增加铸件缩松缩孔缺 陷发生概率，实际生产中可根据需求在型腔或型芯局部添加涂料。最后，对优化后的 工艺进行了数值模拟仿真。 通过生产验证，模拟结果与实际生产相吻合，解决了生产中的难题。本课题通过 数值模拟，提高了工艺的准确性、缩短了开发周期、降低了生产成本、增强了企业竞 争力，对提高企业的经济效益有现实意义。 关键词：充型；凝固；数值模拟；工艺优化 I 山东理工大学硕士学位论文 ABSTRACT Abstract In this paper, the main research is numerical simulation and technique optimization of the casting process of the large machine bed. As an emerging industry of computer numerical simulation has already more and more be accepted and used in foundry enterprises. General enterprise is mainly simulating small and medium-sided castings, but the experience of large machine numerical simulation is lacking. Numerical simulation and technique optimization of the casting process of the large machine bed has scientific theory significance for traditional casting. The study of casting mould filling and solidification process of large machine bed were did by numerical simulation using Anycasting software. First, the foundation of numerical simulation is the three-dimensional molding of machine bed, after designing the modeling, import it to Anycasting software, then by using meshing function of software give the bed a finite grid division establish the model of casting analysis. Fixed the parameters of casting process and then pouring. Filling and solidification process were did by data simulation and research, analyzing the flow and temperature filed changes of this process and forecasting the defects. Next, the effects o