铝合金GIS罐体低压铸造的数值模拟与工艺优化-材料加工工程专业毕业论文.docxVIP

铝合金 GIS 罐体低压铸造的数值模拟与工艺优化 摘要 SF6 封闭式组合继电器（GIS）是具有国际领先技术的输变电系列产品之一，其关 键部件之一是高压开关罐体。我国目前多是采用砂型铸造，产品容易产生渗漏，合格 率低、成本高。新工艺以某厂 100-0003 号罐体为研究对象，采用低压整体铸造方法， 提出了优化设计方案并进行了模拟凝固过程及结果分析。 采用卧筒环形缝隙式浇注系统设计方案，解决了罐体充型困难的问题。根据低压 铸造充型流动的特点，应用 UG 三维造型软件和 ProCAST 模拟仿真软件对高压开关 铝合金罐体低压铸造充型和凝固进行数值模拟。 由于该厂原工艺生产出的铸件总是出现缩松缩孔缺陷，通过对不同改进的工艺方 案进行数值模拟，最终确立了卧式的浇注方式下在铸件底部圆形凸台两侧各加一个肋 板，避免了原工艺充型过程的不平稳与不对称，帮助两侧位置进行补缩。对于铸件顶 部的补缩需求，采取了引入一个浇道到顶部凸台，使得顶部凸台凝固滞后于浇道的凝 固，形成补缩作用，消除缩松缩孔。 根据对不同浇注温度和不同充型压力的模拟结果，分析了凝固过程缺陷的产生原 因，提出了缺陷的预测方法，确定了生产高压开关铝合金罐体新的工艺参数，浇注温 度为 T=700℃，充型压力为 P=0.023MPa。 关键词： GIS 罐体;铝合金;低压铸造;数值模拟 A Study on the Optimized Design and Numerical Simulation of Low Pressure Casting Technology of Aluminum Alloy GIS Tank ABSTRACT SF6 enclosed combination relay (GIS) is one of the lea d power transmission products with advance technology of the world. The high voltage switch tank is one of its key components which is usually made in China by sand -shell molding casting resulting in leakage, low pass rate and high cost of the product. In this thesis, the optimum design was proposed and its solidification process was analysed based on the low pressure casting technology to produce a type of 100-0003 GIS tank. Based on the low pressure casting characteristics, a lying tube -annular-gap type casting system was adopted to solve the problem of filling difficulty. The UG 3D modeling software and ProCAST simulation software were used numerical simulate the casting process and solidification process of the high -voltage switchgear aluminum alloy tank. There often exist shrinkage cavities in the products made by using the original sand-shell-molding. Through numerical simulation for different process, it was determined to add a rib plate on each side of the circular lug at the bottom of the casting with the lying casting system. To satisfy the making the top lugs’ solidification sequence later than that of the sprue runner and eliminating the shrinkage porosity. According to the simulation results to the differ