铸钢件活门产品工艺研发及数值模拟

Development and Numerical Simulation of Casting Process for Steel Casting Main Valve Plug

运用传统方法完成了对铸钢件抽水蓄能机组活门产品的铸造工艺设计。根据活门壁厚大的结构特点,同时设计8个内浇道对铸件进行浇注,在铸件内部设计一个明冒口,在其侧面设计冷铁,以确保铸件的顺序凝固。建立铸件的三维实体模型,运用MAGMA铸造模拟软件对铸钢件活门的凝固过程进行了模拟计算;模拟结果表明,在铸件的厚大处和冒口颈的交接处产生了缩孔、缩松缺陷。根据数值模拟结果并结合理论分析,通过改变冒口颈和冒口尺寸的方法,对铸造工艺进行优化。最终模拟结果显示,优化工艺能将缺陷转移到冒口中,实现了顺序凝固,从而最大程度地消除了铸造缺陷,获得了合理的铸造工艺方案。

The casting process of steel casting main valve plug for pumper storage units was designed by using traditional methods. Because of the heavy spherical valve for pumper storage units, the eight gates were adopted, and an open riser along with chills were designed in the casting to ensure progressive solidification.The3-D model of the casting was built and the Magma casting simulation software was employed to simulate the solidification process of the steel casting.The simulation showed that the shrinkage defects forms at the joint between the feeder neck and the shell.According to the results and combining with theoretical analysis,the casting process was improved by changing the size of feeder neck and the number of the riser.The results showed that the shrinkage only appeared at the riser because of the progressive solidification, the shrinkages in the casting were removed.Then the reasonable casting process was determined.