数值模拟技术在大型锻件生产中的应用

Application of Numerical Simulation Technology in the Heavy Forging Production

数值模拟技术在保证工件质量、减少材料消耗、提高生产效率、缩短试制周期等方面显示出无可比拟的优越性。在钢锭凝固方面,有限元模拟程序MIPS可以分析凝固过程中温度场的分布,确定不同时刻凝固前沿的位置,而且能预测缩孔和疏松的位置及尺寸。使用该程序对220吨钢锭的生产工艺进行优化,成功地解决了疏松进入锭身的问题。在锻造方面,已开发出了基于ANSYS的三维大变形弹塑性、弹粘塑性程序,可以分析复杂的三维金属塑性成形问题。热处理专用软件NSHT不仅可以分析加热、淬火及回火过程中温度场分布,而且可以给出应力的分布及相态的变化过程,并已在实际生产中取得了成功。

Numerical simulation technology has incomparable superiority in respect of the assuring parts quality, reducing material consumption, raising production efficiency and cutting trial - production cycle. For ingot solidification,the distribution of temperature field in solidification process and the forward position of the ingot solidification in various time can be analyzed and determined by the finite element simulation software MIPS,the position and size of shrinkage cavity and porosity can also be detected by this software ,and the optimized production procedure for 200t ingot by this software successfully solve a problem of the porosity in ingot body. With respect to forging method,the three -dimension large deformed elastic-plastic and elastic-bonded-plastic program based on the ANSYS have been developed and used for analyzing the complex three- dimension metal plasticity formed question. In addition,the special software NSHT for heat treatment not only can analyze the distribution of temperature field during heating,hardening and tempering,but also can provide the distribution of stress and the change process of phase. This software has been used successfully for full-scale production.