熔模铸件尺寸控制的数字孪生建模关键技术与应用

Key Technology and Application of Digital Twin Modeling for Deformation Control of Investment Casting

熔模铸造工艺流程长、工序多,铸件成型过程孤岛控制,存在尺寸超差问题。本工作基于节点法向量和最近邻点,提出熔模铸造工艺全节点位移传递的计算方法,解决熔模铸件成型多流程的数据孤岛问题。研究蜡模注射成型和铸件凝固过程工艺参数-尺寸偏差的关系,为数字孪生建模提供数据模型。对环套环特征件建立铸件模具反变形设计和铸件多流程下工艺优化的数字孪生应用。该数字孪生模型应用于设计阶段,反变形设计出模具内腔的三维几何模型。模拟结果表明,铸件所有节点位移偏差在0.04 mm以下。应用于流程之间的工艺控制,根据前一工序下尺寸偏差,进行后续工艺优化调控。

Investment casting processes are controlled separately for its complex casting system,resulting in the dimensional out of tolerance.A calculation method for node displacement transfer is proposed based on the node normal vector and the nearest neighbor points in investment casting;the relationship between injection parameters,dimensional deviation in injected wax pattern,and casting solidification is studied,which provides a data model for digital twin.The digital twin is applied to the antideformation design and process optimization under a multiprocess for ring-to-ring casting.In the design stage,the geometric model of the mold cavity is designed via reverse deformation,and the error between the simulation results of the casting after the antideformation design and the target geometric is<0.04 mm.In the casting,the optimal control of the subsequent process is performed according to the dimensional deviation of the previous process.