基于有限元模拟的铸钢车轮凝固工艺优化

Optimization of Solidification Process Design for Bulky Steel Casting Based on Finite Element Simulation

根据有限元模拟原理,基于ANSYS软件环境对机车车轮大型铸钢件的凝固进程三维非稳定温度场进行了数值模拟。通过有限元模拟的反馈信息进行了铸件凝固工艺的优化设计。模拟结果表明,按照传统的比例计算法设计的冒口系统能够保证铸件产品的质量,但冒口数目多,铸件工艺出品率偏低。如果单纯减小冒口尺寸以提高工艺出品率,则车轮铸件的顺序凝固条件将会受到破坏,导致缩孔缩松缺陷产生。通过减少冒口数目并设置冷铁,则可通过冒口和冷铁的联合作用,既保证无缺陷凝固工艺过程的实现,又能提高工艺出品率。通过模拟优化的实施,预测工艺出品率将提高12%。

According to theory of finite element modeling (FEM), a transient 3-D temperature field during solidification process of bulky steel locomotive wheel casting was simulated based on ANSYS environment. The optimization of casting process design was made by means of feedback achieved by FEM. Results indicate that the resier system designed through conventional proportional method based on hot-spot status could insure the quality of product but the product yield (PY) was insufficient due to large number of risers. Meanwhile, If for the purpose of better PY keeping other conditions unvaried only simply to reduce the sizes of risers, pore and porosity defects would appear in casting, because the sequential solidifying premise of temperature field was not satisfied. The present study shows a positive optimized effect that guaranteed the free of defects in solidifying process by combining the chill effect when the riser number was reduced. The PY is increased by up to 12 percent.