ZTC4钛合金复杂薄壁件铸造过程收缩与变形模拟及尺寸控制

Shrinkage and Deformation Simulation and Size Control of ZTC4 Titanium Alloy Complex Thin-wall Casting Process

针对钛合金薄壁件铸造工艺中普遍存在的由于内部结构差异引发的不均匀金属收缩,进而导致铸件尺寸难以精确控制的关键问题,利用华铸CAE软件进行了深入分析。通过数值模拟预测了在石墨铸造过程中钛合金薄壁件的具体变形量,并基于此数据,提出了通过预先在设计阶段增加补正量的方法来平衡铸造收缩的影响。数据结果显示,通过预先设计补正量的方式可以保证尺寸精度达到CT7,预变形控制后的变形量在-0.250~0.315 mm之间,整体呈正态分布,变形量为0.035 mm,约占35%。而变形量为-0.250和0.315 mm的区域累计不足2%,整体变形量小,且变形量相差小。通过实施该方法,成功解决了钛合金薄壁铸件在生产过程中出现的尺寸超差问题,提高了铸件尺寸精度和产品质量,从而推动了高端钛合金薄壁铸件在航空航天、医疗器械等领域的大规模应用和工业化进程。

To address the critical issue prevalent in the casting process of thin-walled titanium alloy components,where uneven metal shrinkage caused by internal structural discrepancies leads to challenges in precisely controlling the dimensions of castings,an in-depth numerical simulation analysis was conducted using Huazhu CAE software.The specific deformation of thin-walled titanium alloy parts during graphite casting was predicted via numerical simulation.Based on the data,an innovative approach was proposed to counterbalance the effect of casting shrinkage by incorporating compensatory volumes at the design stage beforehand.The results indicate that adopting this predesign compensation strategy enables dimensional accuracy to meet CT7 standards,with deformations ranging from-0.250 to 0.315 mm after predeformation,generally following a normal distribution.A deformation of 0.035 mm is the most common,accounting for approximately 35%of the cases,while regions with deformations of-0.250 and 0.315 mm cumulatively represent less than 2%,indicating minimal overall deformation with narrow variation.The implementation of this method successfully resolves the dimension tolerance issues encountered during the production of titanium alloy thin-wall castings,enhancing both the dimensional precision and product quality.Consequently,it has facilitated the large-scale application and industrialization of high-end titanium alloy thin-wall castings in sectors such as aerospace and medical equipment.