Data-driven casting defect prediction model for sand casting based on random forest classification algorithm

The complex sand-casting process combined with the interactions between process parameters makes it difficult to control the casting quality,resulting in a high scrap rate.A strategy based on a data-driven model was proposed to reduce casting defects and improve production efficiency,which includes the random forest(RF)classification model,the feature importance analysis,and the process parameters optimization with Monte Carlo simulation.The collected data includes four types of defects and corresponding process parameters were used to construct the RF model.Classification results show a recall rate above 90% for all categories.The Gini Index was used to assess the importance of the process parameters in the formation of various defects in the RF model.Finally,the classification model was applied to different production conditions for quality prediction.In the case of process parameters optimization for gas porosity defects,this model serves as an experimental process in the Monte Carlo method to estimate a better temperature distribution.The prediction model,when applied to the factory,greatly improved the efficiency of defect detection.Results show that the scrap rate decreased from 10.16% to 6.68%.

Effects of cement content, polypropylene fiber length and dosage on fluidity and mechanical properties of fiber-toughened cemented aeolian sand backfill

Using aeolian sand(AS)for goaf backfilling allows coordination of green mining and AS control.Cemented AS backfill(CASB)exhibits brittle fracture.Polypropylene(PP)fibers are good toughening materials.When the toughening effect of fibers is analyzed,their influence on the slurry conveying performance should also be considered.Additionally,cement affects the interactions among the hydration products,fibers,and aggregates.In this study,the effects of cement content(8wt%,9wt%,and 10wt%)and PP fiber length(6,9,and 12 mm)and dosage(0.05wt%,0.1wt%,0.15wt%,0.2wt%,and 0.25wt%)on fluidity and mechanical properties of the fibertoughened CASB(FCASB)were analyzed.The results indicated that with increases in the three aforementioned factors,the slump flow decreased,while the rheological parameters increased.Uniaxial compressive strength(UCS)increased with the increase of cement content and fiber length,and with an increase in fiber dosage,it first increased and then decreased.The strain increased with the increase of fiber dosage and length.The effect of PP fibers became more pronounced with the increase of cement content.Digital image correlation(DIC)test results showed that the addition of fibers can restrain the peeling of blocks and the expansion of fissure,and reduce the stress concentration of the FCASB.Scanning electron microscopy(SEM)test indicated that the functional mechanisms of fibers mainly involved the interactions of fibers with the hydration products and matrix and the spatial distribution of fibers.On the basis of single-factor analysis,the response surface method(RSM)was used to analyze the effects of the three aforementioned factors and their interaction terms on the UCS.The influence surface of the two-factor interaction terms and the three-dimensional scatter plot of the three-factor coupling were established.In conclusion,the response law of the FCASB properties under the effects of cement and PP fibers were obtained,which provides theoretical and engineering guidance for FCASB filling.

Sand deposit-detecting method and its application in model test of sand flow

Against the background of the sand-flow foundation treatment engineering of Guangzhou Zhoutouzui variable cross-section immersed tunnel, a kind of sand deposit-detecting method was devised on the basis of full-scale model test of sand-flow method. The real-time data of sand-deposit height and radius were obtained by the self-developed sand-deposit detectors. The test results show that the detecting method is simple and has high precision. In the use of sand-flow method, the sand-carrying capability of fluid is limited, and sand particles are all transported to the sand-deposit periphery through crater, gap and chutes after the sand deposit formed. The diffusion range of the particles outside the sand-deposit does not exceed 2.0 m. Severe sorting of sand particles is not observed because of the unique oblique-layered depositing process. The temporal and spatial distributions of gap and chutes directly affect the sand-deposit expansion, and the expansion trend of the average sand-deposit radius accords with quadratic time-history curve.

Thermal stress analysis method considering geometric effect of risers in sand mold casting process

Solidif ication and f luid f low analysis using computer simulation is a current common practice. There is also a high demand for thermal stress analysis in the casting process because casting engineers want to control the defects related to thermal stresses, such as large deformation and crack generation during casting. The riser system is an essential part of preventing the shrinkage defects in the casting process, and it has a great inf luence on thermal phenomena. The analysis domain is dramatically expanded by attaching the riser system to a casting product due to its large volume, and it makes FEM mesh generation diff icult. However, it is diff icult to study and solve the above proposed problem caused by riser system using traditional analysis methods which use single numerical method such as FEM or FDM. In this paper, some research information is presented on the effects of the riser system on thermal stress analysis using a FDM/FEM hybrid method in the casting process simulation. The results show the optimal conditions for stress analysis of the riser model in order to save computation time and memory resources.

Single-factor analysis and interaction terms on the mechanical and microscopic properties of cemented aeolian sand backfill

The use of aeolian sand(AS)as an aggregate to prepare coal mine cemented filling materials can resolve the problems of gangue shortage and excessive AS deposits.Owing to the lack of research on the mechanism of cemented AS backfill(CASB),the response surface method(RSM)was adopted in this study to analyze the influence of ordinary Portland cement(PO)content(x_(1)),fly ash(FA)-AS(FA-AS)ratio(x_(2)),and concentration(x_(3))on the mechanical and microscopic properties of the CASB.The hydration characteristics and internal pore structure of the backfill were assessed through thermogravimetric/derivative thermogravimetric analysis,mercury intrusion porosimetry,and scanning electron microscopy.The RSM results show that the influence of each factor and interaction term on the response values is extremely significant(except x_(1)x_(3),which had no obvious effect on the 28 d strength).The uniaxial compressive strength(UCS)increased with the PO content,FA-AS ratio,and concentration.The interaction effects of x_(1)x_(2),x_(1)x_(3),and x_(2)x_(3) on the UCS at 3,7,and 28 d were analyzed.In terms of the influence of interaction items,an improvement in one factor promoted the strengthening effect of another factor.The enhancement mechanism of the curing time,PO content,and FA-AS ratio on the backfill was reflected in the increase in hydration products and pore structure optimization.By contrast,the enhancement mechanism of the concentration was mainly the pore structure optimization.The UCS was positively correlated with weight loss and micropore content but negatively correlated with the total porosity.The R^(2) value of the fitting function of the strength and weight loss,micropore content,and total porosity exceeded 0.9,which improved the characterization of the enhancement mechanism of the UCS based on the thermogravimetric analysis and pore structure.This work obtained that the influence rules and mechanisms of the PO,FA-AS,concentration,and interaction terms on the mechanical properties of the CASB provided a certain theoretical and engineering guidance for CASB filling.

Numerical Optimization of Sand Casting Parameters Using the Dantzig’s Simplex Method

This study adopts the Dantzig’s Simplex method to investigate optimization of sand casting parameters for optimum service performance. Some process variables and mechanical properties were adapted into the Simplex method. Aluminium alloy samples were cast, machined and subjected to a series of mechanical tests. From the body of data collected, linear functions and constraint equations were formulated and employed in the Dantzig’s Simplex method for optimization of process parameters. The results showed that the Simplex method can be adapted for studying performance opti- mization of castings.

Preparation of coated sand for selective laser sintering and optimization of baking process of sand moulds

A cold method was used to prepare coated sand for application in the selective laser sintering(SLS)process.Tensile strength,loss on ignition,gas evolution,and accuracy of the SLS samples were tested and analyzed,and the baking process was thoroughly investigated.Compared with coated sand prepared by the hot method,the cold method yields a more uniform and complete resin film on the sand's surface,resulting in enhanced tensile strength and accuracy.Additionally,the cold method requires a lower binder content to meet the same strength requirements,thereby minimizing gas evolution,reducing porosity defects,and ultimately improving casting quality.The coated sand samples prepared through the cold method exhibit superior accuracy,with a size error of within±0.4 mm.In contrast,the coated sand samples prepared by the hot method display a lower accuracy,with an average negative error of 2.1993 mm.The highest tensile strength could be attained by controlling the baking temperature within a suitable range(180-190°C),which can effectively reduce the generation of gas,thus contributing to improved overall performance.

砂土-混凝土接触面剪切带细观变形特征的试验研究

接触面剪切带的细观变形特征是研究结构物与土体相互作用的核心问题。为探明砂土-混凝土接触面剪切带变形特征,利用大型直剪仪开展砂土-混凝土接触面直剪试验,采用灌砂变形标记法实测砂土变形,依据标记线剪应变沿竖向的变化特征对砂土变形区域进行划分。在此基础上,研究粗糙度、法向应力和密实度对砂土-混凝土接触面剪切带细观变形特征的影响规律。研究结果表明:1)砂土可分为非剪切区、过渡区和应变集中区,应变集中区仅存在剪切面之上。2)规则型接触面的上剪切带厚度均值为33D_(50),远大于下剪切带9D_(50)和“光滑”接触面剪切带厚度20.4D_(50)。3)密实度对剪切带及其过渡区厚度的影响微弱,而粗糙度对其影响显著;法向应力、密实度对应变集中区厚度影响有限,应变集中区厚度随粗糙度的增大近似线性增大;应变集中区长度随粗糙度的增大先增大后减小,随密实度的增大近似线性增大,随法向应力增大而减小。4)随剪切位移增大,上剪切带厚度不断增大而下剪切带厚度先增大后保持基本不变,应变集中区的长度增大,但剪切位移对应变集中区厚度的影响有限。5)获得归一化剪切带厚度取值h_(t)/D_(50)与D_(50)的关系,在有限元模拟规则型结构与砂土的相互作用时,建议砂土体细化网格单元的范围不小于最大剪切带厚度37D_(50)。研究成果深化了砂土-规则型接触面剪切带变形特征的认识,可为大粗糙度、带肋桩的承载变形特性的精细化有限元模拟分析提供重要参考和依据。

不同推进比下螺旋桩在砂土中安装力的离散元研究

螺旋桩作为一种颇具潜力的海上风电基础形式,其安装问题是螺旋桩能否成功应用在海上风电工程中的关键。基于离散元方法,采用PFC^(3D)模拟分析了螺旋桩在不同推进比下安装时的桩身受力情况以及对周围土体的影响。宏观上,研究了螺旋桩在不同推进比下安装时螺旋桩连杆侧壁、连杆端部、螺旋叶片上下表面的受力变化规律;微观上,分析了螺旋桩安装过程中桩周土体孔隙率、配位数及应力变化规律。研究表明:随着推进比的减小,螺旋桩安装时受到的竖向力与扭矩也随之降低,对桩周土体的扰动也更小;螺旋桩在推进比为1时安装与在推进比小于1时安装存在两种不同的安装机制。研究结果对进一步确定螺旋桩在不同推进比下的安装条件具有一定意义。

Influence of artificial freezing onliquefaction characteristics of Nanjing sand

Purpose–This study purposes to study the influence of artificial freezing on the liquefaction characteristics of Nanjing sand,as well as its mechanism.Design/methodology/approach–was studied through dynamic triaxial tests by means of the GDS dynamic triaxial system on Nanjing sand extensively discovered in the middle and lower reaches of the Yangtze River under seismic load and metro train vibration load,respectively,and potential hazards of the two loads to the freezing construction of Nanjing sand were also identified in the tests.Findings–The results show that under both seismic load and metro train vibration load,freeze-thaw cycles will significantly reduce the stiffness and liquefaction resistance of Nanjing sand,especially in the first freezethaw cycle;the more freeze-thaw cycles,the worse structural behaviors of silty-fine sand,and the easier to liquefy;freeze-thaw cycles will increase the sensitivity of Nanjing sand’s dynamic pore pressure to dynamic load response;the lower the freezing temperature and the effective confining pressure,the worse the liquefaction resistance of Nanjing sand after freeze-thaw cycles;compared to the metro train vibration load,the seismic load in Nanjing is potentially less dangerous to freezing construction of Nanjing sand.Originality/value–The research results are helpful to the construction of the artificial ground freezing of the subway crossing passage in the lower reaches of the Yangtze River and to ensure the construction safety of the subway tunnel and its crossing passage.

基于颗粒特征与预设变形的人工砂土变形图像生成方法及应用

图像变形分析方法是当前土力学与岩土工程领域的一种重要变形测试技术,散斑图像作为其发展、应用和可靠性评价的常用工具,是否反映真实土体图像特征和变形分析可靠性尚有待解答。以福建标准砂为样本,基于土体图像特征分析及与散斑图像对比,提出了一种描述砂土图像和变形特征的人工图像生成方法,利用建立的4种变形坐标解析公式和生成序列变形图像,对国际代表性RG-DIC和PIVlab法可靠性进行评价。结果表明:散斑图像与真实砂土图像在纹理、圆度、色值等方面存在显著差异,提出的人工图像生成方法能有效控制土颗粒组分、圆度、色值等分布参数,反映了真实土体图像特征;生成的序列变形图像增加了时间变量和任意变形函数功能,为动态和复杂变形分析可靠性评价建立条件。散斑图像明显低估了RG-DIC和PIVlab法对土体变形的分析误差,原因为黑色背景、白色亮斑构成的纹理特征更具辨识性;RG-DIC法的分析准确性与稳定性明显优于PIVlab法,而不同变形条件下两种方法分析误差呈一致趋势,当剪应变≤10^(-3)时误差快速上升。研究方法与成果,为土体图像变形分析方法发展、应用和可靠性评价提供了重要支撑和参考。

密砂中单盘螺旋锚安装效应对抗拔能力影响的数值分析

目的研究密砂中单盘螺旋锚安装过程中锚周土体变形特性及其对抗拔能力的影响,为螺旋锚基础精细化设计提供技术支撑。方法利用MatDEM软件建立密砂中螺旋锚安装及拉拔过程的数值计算模型,通过与室内模型试验结果对比标定颗粒微观力学参数,进而分析钻入和预埋两种安装方式下不同埋深和盘径的螺旋锚安装效应及上拔承载力。结果当H/d w≤10时,钻入安装的极限上拔力较预埋低,当H/d w>10后,安装方式带来承载力差别不再随埋深增加而增加;随着盘径增大,两种安装方式下螺旋锚的承载能力均表现出增大的趋势,钻入方式下的Q ut比预埋下的Q up降低量从33%增至53%,预埋方式螺旋锚的承载能力高于钻入。结论钻入安装螺旋锚的上拔承载力低于预埋方式的承载力,但当埋深比超过10后,安装扰动对承载力的影响随着深度变化很小;随着盘径增加,安装扰动对极限上拔承载力的影响增大,相较于埋深变化带来的安装扰动差异,盘径变化带来的影响更明显。

走航式电阻率法探测平原水库库底砂体效果分析及应用

平原水库库底沉积层中的砂体会对水库运行以及穿过库底地下空间工程建设的安全造成不可忽视的影响,一种快速且准确识别库底砂体空间位置的探测手段可为破解以上问题提供技术支持。本文以位于黄河流域的济南鹊山水库为研究区,基于数值模拟与原位探测结果,分析评价了走航式电阻率法识别平原水库库底砂体的最优装置参数和能力,并将所得结论在原位探测中应用、验证。研究结果表明,选用通用走航探测航速(航速2.5 m/s)对平原水库(水深6 m)进行探测时,走航式电阻率法对埋深浅(埋深<30 m)、厚度大(厚度>6 m)的砂体有较好的理论分辨能力。对于薄层深埋砂体(厚度<2 m,埋深>10 m)则难以识别;砂体探测顶、底界位置与实际顶、底界位置间的偏移距离与砂体顶界埋深、砂体长度呈正相关关系。砂体厚度增大会提高不同顶界埋深条件下砂体界面偏移距离差异,偏移距离正相关于深埋砂体厚度,负相关于浅埋砂体厚度;建立了修正原位探测结果并识别砂体的方法。基于原位探测结果所识别的砂体形态并不精确,其厚度普遍厚于实际砂体厚度约0~3 m。厚度小于3 m的薄砂体则难以被该方法识别。

TRD工法在赣江尾闾围堰防渗工程中的应用

赣江下游尾闾综合整治工程4支枢纽采用TRD工法对防渗墙进行施工,并针对重难点区段调整了施工工艺,该做法克服了地质条件复杂、砂卵砾石地层厚度大、防渗墙深度大等不利因素的影响,施工效率高且安全环保,取得了良好的防渗效果。

循环剪切作用下含可燃冰砂土-开采井界面强度弱化细观机制

含可燃冰砂土呈现埋藏浅、未成岩和强度低的特性。波浪循环荷载作用下含可燃冰砂土-开采井界面弱化特征显著,直接影响井口稳定。采用离散元方法,通过设置波浪循环荷载引起的井筒运动,研究含可燃冰砂土-开采井界面循环剪切力学特性,并从细观角度揭示界面宏观弱化机制。结果表明:可燃冰赋存导致含可燃冰砂土-开采井界面呈显著的强度弱化及剪胀体变特征,且可燃冰饱和度越高,弱化及剪胀越显著;原因在于近井区域含可燃冰砂土在循环剪切作用下形成胶结失效区域,大部分颗粒失去胶结约束,同时少部分胶结未失效的可燃冰颗粒与邻近颗粒形成较大粒径团簇,这些颗粒和团簇翻滚错动且无法充分传递荷载,导致界面产生强度弱化和剪胀体变;法向应力与剪切振幅的增大均会加剧界面试样可燃冰颗粒的胶结失效发展,强度弱化现象更为严重。

砂土边坡桩间水平土拱机理与演变规律离散元分析

抗滑桩等非连续支挡结构在边坡工程中依靠土拱效应安全经济地发挥支护功能。鉴于不同类型砂土的力学性质差异较大,为揭示密砂与松砂土质边坡抗滑桩桩间水平土拱机理与演变规律,采用离散元方法(DEM)模拟支挡砂土水平土拱的成拱过程。在传统力链分析的基础上,提出通过筛选高应力颗粒来研究土拱的形成过程,进一步从细观角度对不同工况土拱效应进行分析,以揭示“应力拱”和“位移拱”的演化过程。研究表明:密砂和松砂中的水平土拱的动态演变过程均表现为3个演化阶段,分别对应于密砂和松砂的剪切性状,即应变软化和应变硬化现象,揭示了砂土边坡桩间土拱效应的演变规律。此外,讨论了宏-微观DEM模拟参数对土拱形成过程与土拱效应性能的影响,结果表明拱跨对于荷载传递效率的影响最大。

基于田口法与CFD的新型除砂装置中冲砂喷嘴性能优化

由于吐哈油田的许多油气井相继进入到成产后期,因此井内出砂已逐渐成为影响产量的主控因素之一。为了提高中后期井的生产效率,减少砂埋产层风险以及实现降本增效,提出一种新型除砂装置。通过充分分析装置的工作原理后,发现此装置可同时实现对井底砂粒或砂层的冲击与携带。由于冲砂喷嘴的结构与具体尺寸对装置整体性能(冲砂深度)影响较大,因此对冲砂喷嘴的结构进行优选。利用田口方法与CFD(数值模拟)共同对冲砂喷嘴的结构尺寸进行优化。定义冲砂深度为试验指标,出口直径、出口圆柱段长径比以及喷嘴收缩角等为控制因子,分别进行分组试验,并利用信噪比与方差分析方法对试验结果进行研究。结果表明:当冲砂喷嘴的出口直径为8 mm、入口直径为16 mm、收缩角为15°、出口圆柱段长度为20 mm、入口圆柱段长度为32 mm时,冲砂喷嘴的性能最好,并且其最远冲砂深度可以达到0.594 m。与优化前的喷嘴对比,优化后的喷嘴冲砂能力提高了31.3%。

宽级配土离心试验地基模型落雨法分层机制与数值模拟

落雨法因其在模型制备过程与自然条件下砂土沉积过程相似,因而成为土工离心试验地基模型常用的模型制备手段,但是有关落雨法研究主要集中于相对密实度控制,而对于分层现象关注较少,尤其宽级配土。针对宽级配土落雨法制备过程出现的分层现象,利用PFC3D数值模拟软件,探讨了落雨法制备过程分层现象的物理机制和出砂口落距、移动速度、宽度对分层现象的影响。结果表明:在真空介质中,粗细颗粒不出现分层现象;而在非真空介质中,粗、细颗粒出现了分层现象,原因为非真空环境下粗、细颗粒下落过程中产生了相对速度差,内在机制为粗、细颗粒半径不同受到平均表面流体阻力不同,从而造成不同粒径颗粒分离现象;随环境介质密度的增加,粗、细颗粒在下落过程中更易于发生分离,出砂口落距、移动速度和流量对分层现象具有一定程度影响。

考虑颗粒破碎影响的钙质砂中海底管道贯入机制研究

通过离心机模型试验,结合离散元数值分析对钙质砂中海底管道竖向贯入机制进行了研究。研究结果显示,钙质砂中管道竖向贯入阻力与埋深基本呈线性关系,其值大致等于管-土接触宽度与静力触探试验(cone penetration test,简称CPT)中相同深度锥尖阻力的乘积。当管道埋深较小时,由于土体变形主要以颗粒重排挤密为主,管道竖向贯入阻力几乎不受颗粒强度影响;当管道埋深较大时,管道竖向贯入阻力随着颗粒强度的降低以及颗粒破碎的加剧而减小。钙质砂中管道竖向贯入机制主要表现为典型的冲剪破坏,土体变形主要集中在管道底部,且水滴状变形区域随着颗粒破碎的加剧逐渐收缩。颗粒破碎从管道底部向远离管道径向发展,大量贴近管道底部的颗粒发生连续破碎,少量远离管道的颗粒发生独立破碎。颗粒破碎导致管道底部土体中的集中应力释放,颗粒破碎越多,应力释放导致管道竖向贯入阻力减小的现象越明显。

SAND-II解谱的不确定度分析

简介了利用SAND-II解中子谱的基本原理;分析了影响谱不确定度的因素,详细描述了利用蒙特卡罗方法分析谱不确定度的一般步骤:包括随机样本的选取、样本标准偏差的确定、谱的方差、标准偏差(标准不确定度)计算等。通过对脉冲反应堆辐照腔中子能谱的测量计算,总结了提高SAND-II解谱准确性的主要途径。