ZL205 A alloys with large thin-walled shape were continuously processed by coupling travelling magnetic fields(TMF)with sequential solidification,to eliminate the shrinkage defects and optimize the mechanical performa...ZL205 A alloys with large thin-walled shape were continuously processed by coupling travelling magnetic fields(TMF)with sequential solidification,to eliminate the shrinkage defects and optimize the mechanical performance.Through experiments and simulations,the parameter optimization of TMF and the influence on feeding behavior,microstructure and properties were systematically studied.The results indicate that the magnetic force maximizes at the excitation current of 20 A and frequency of 200 Hz under the experimental conditions of this study,and increases from center to side-walls,which is more convenient to process thin-walled castings.TMF can break secondary dendritic arm and dendrites overlaps,widen feeding channels,prolong the feeding time,optimize the feeding paths,eliminate shrinkage defects and improve properties.Specifically,for as-cast state,TMF with excitation current of 20 A increases ultimate tensile strength,elongation and micro-hardness from 186 MPa,7.3%and 82.1 kg/mm^(2) to 221 MPa,11.7%and 100.5 kg/mm^(2),decreases porosity from 1.71%to 0.22%,and alters brittle fracture to ductile fracture.展开更多
Shrinkage cavity may be detrimental to mechanical performances of casting parts.As a consequence,design engineers often use overly large safety factors in many designs due to insufficient understanding of quantitative...Shrinkage cavity may be detrimental to mechanical performances of casting parts.As a consequence,design engineers often use overly large safety factors in many designs due to insufficient understanding of quantitative effects of shrinkage cavity defects.In this paper,process of Al alloy wheel impact test was computationally analyzed for both the wheel models with and without shrinkage cavity defects.Based on shrinkage cavity data obtained from industrial CT (Computerized Tomography),the shrinkage cavity defects were modeled with SSM (Shape Simplification Method),which reconstructs shrinkage cavity defects to hollow spheroid primitives.After the impact simulation was conducted,the results show that under impact test condition,the wheel considering shrinkage cavity defects may fracture while the sound-assumed wheel may not.展开更多
The shrinkage defect of a ductile iron casting is attributed to the volume variations occurring in solidification, which consist of liquid contraction, solidification shrinkage, graphitization expansion, and mold cavi...The shrinkage defect of a ductile iron casting is attributed to the volume variations occurring in solidification, which consist of liquid contraction, solidification shrinkage, graphitization expansion, and mold cavity enlargement. Based on this understanding, a mathematical model for predicting the shrinkage defect of the casting is developed, in which the volume variations of the casting in soli- dification are numerically simulated, especially, the mold cavity enlargement is quantitatively calculated. Moreover, the reliability of the model is verified in production and experiment.展开更多
Shrinkage cavities and large inclusions are serious internal defects of heavy steel ingot and influence the quality of subsequent forgings. In order to remove these two types of defects, a 70 t 12Cr2Mo1 heavy ingot fa...Shrinkage cavities and large inclusions are serious internal defects of heavy steel ingot and influence the quality of subsequent forgings. In order to remove these two types of defects, a 70 t 12Cr2Mo1 heavy ingot fabricated by vacuum carbon de-oxidation process was sectioned and investigated by means of structure observation and EDS analysis. To further study the forming mechanism of shrinkage and inclusion defects and find possible solutions, simulation on pouring and solidification processes was also carried out using Fluent and ProCAST software, respectively. Results show that the shrinkage defects do not appear in the middle-upper part of the ingot. The critical value of shrinkage cavity criterion is ascertained as 0.013 on the basis of sectioning investigation and simulation results, which can be used in computer simulation to predict and avoid shrinkage defects in production of 12Cr2Mo1 ingots with different weights. However, large inclusions are found at the bottom of the ingot body. The bad thermal conditions of the ingot surface and large amount of entrained slag are the main origin of the large inclusions. The simulation result of the pouring process shows that large inclusions may be eliminated by combined measures of improving the top thermal condition and controlling the height of rudimental molten steel in the ladle to above 300 mm.展开更多
Most of the shrinkage porosity criteria only consider internal thermal conditions, but ignore external conditions, such as pressure. Therefore, to some castings with a relatively high molten metal hydrostatic pressure...Most of the shrinkage porosity criteria only consider internal thermal conditions, but ignore external conditions, such as pressure. Therefore, to some castings with a relatively high molten metal hydrostatic pressure or atmosphere pressure, the shrinkage porosity prediction will not be accurate enough. In order to solve this problem, this work studies and improves a known shrinkage porosity criterion ‘Xue Criterion’. The pressure is introduced into the criterion function and a relationship between ‘Xue Criterion’ and the pressure is established. The modified ‘Xue Criterion’ function can be expressed as p0Gτ/τ. Compared with the previous experimental work, the prediction result from the new shrinkage criterion has a good agreement with the experimental result, and it is more accurate than the original ‘Xue Criterion’.展开更多
Shrinkage porosity is a type of random distribution defects and exists in most large castings. Different from the periodic symmetry defects or certain distribution defects, shrinkage porosity presents a random "c...Shrinkage porosity is a type of random distribution defects and exists in most large castings. Different from the periodic symmetry defects or certain distribution defects, shrinkage porosity presents a random "cloud-like" configuration, which brings difficulties in quantifying the effective performance of defected casting. In this paper, the influences of random shrinkage porosity on the equivalent elastic modulus of QT400-18 casting were studied by a numerical statistics approach. An improved random algorithm was applied into the lattice model to simulate the "cloud-like" morphology of shrinkage porosity. Then, a large number of numerical samples containing random levels of shrinkage were generated by the proposed algorithm. The stress concentration factor and equivalent elastic modulus of these numerical samples were calculated. Based on a statistical approach, the effects of shrinkage porosity's distribution characteristics, such as area fraction, shape, and relative location on the casting's equivalent mechanical properties were discussed respectively. It is shown that the approach with randomly distributed defects has better predictive capabilities than traditional methods. The following conclusions can be drawn from the statistical simulations:(1) the effective modulus decreases remarkably if the shrinkage porosity percent is greater than 1.5%;(2) the average Stress Concentration Factor(SCF) produced by shrinkage porosity is about 2.0;(3) the defect's length across the loading direction plays a more important role in the effective modulus than the length along the loading direction;(4) the surface defect perpendicular to loading direction reduces the mean modulus about 1.5% more than a defect of other position.展开更多
Thin-walled tube numerical control （NC） bending is a tri-nonlinear physical process with multi-defect and multi-die constraints. The clearance on each contact interface is the major factor to indicate the contact co...Thin-walled tube numerical control （NC） bending is a tri-nonlinear physical process with multi-defect and multi-die constraints. The clearance on each contact interface is the major factor to indicate the contact conditions. A three-dimensional-finite element （3D-FE） model is established to consider the realistic dynamic boundary conditions of multiple dies under ABAQUS/Explicit platform. Combined with experiment, numerical study on bending behavior and bendability under different clearance between tube and various dies is conducted in terms of wrinkling, wall thinning and cross section deformation. The results show that （1）with smaller clearance of tube-wiper die and tube-mandrel, the wrinkling can be restrained while the wall thinning It and cross-section deformation Id increase; while excessive small clearance blocks tube materials to flow past tangent point and causes piles up, the onset of wrinkling enhances It and Id. （2）Both It and Id decrease with smaller clearance of tube-pressure die; the wrinkling possibility rises with larger clearance on this interface if the mandrel’s freedom along Y-axis is opened; smaller clearance of tube-bend die prevents wrinkling while increases It, and the clearance on this interface has little effect on Id. （3）A modified Yoshida buckling test （YBT） is used to address the wrinkling mechanisms under normal constraints in tube bending： the smaller clearance may restrain wrinkling efficiently; the smaller wall thickness, the less critical clearance needed; the critical clearance for tube bending 38 mm×1 mm×57 mm （tube outer diameter×wall thickness×centerline bending radius） equals about 20% of initial wall thickness.展开更多
基金financial supports from the National Key Research and Development Program of China(2017YFA0403804)the National Natural Science Foundation of China(51425402,51671073)。
文摘ZL205 A alloys with large thin-walled shape were continuously processed by coupling travelling magnetic fields(TMF)with sequential solidification,to eliminate the shrinkage defects and optimize the mechanical performance.Through experiments and simulations,the parameter optimization of TMF and the influence on feeding behavior,microstructure and properties were systematically studied.The results indicate that the magnetic force maximizes at the excitation current of 20 A and frequency of 200 Hz under the experimental conditions of this study,and increases from center to side-walls,which is more convenient to process thin-walled castings.TMF can break secondary dendritic arm and dendrites overlaps,widen feeding channels,prolong the feeding time,optimize the feeding paths,eliminate shrinkage defects and improve properties.Specifically,for as-cast state,TMF with excitation current of 20 A increases ultimate tensile strength,elongation and micro-hardness from 186 MPa,7.3%and 82.1 kg/mm^(2) to 221 MPa,11.7%and 100.5 kg/mm^(2),decreases porosity from 1.71%to 0.22%,and alters brittle fracture to ductile fracture.
文摘Shrinkage cavity may be detrimental to mechanical performances of casting parts.As a consequence,design engineers often use overly large safety factors in many designs due to insufficient understanding of quantitative effects of shrinkage cavity defects.In this paper,process of Al alloy wheel impact test was computationally analyzed for both the wheel models with and without shrinkage cavity defects.Based on shrinkage cavity data obtained from industrial CT (Computerized Tomography),the shrinkage cavity defects were modeled with SSM (Shape Simplification Method),which reconstructs shrinkage cavity defects to hollow spheroid primitives.After the impact simulation was conducted,the results show that under impact test condition,the wheel considering shrinkage cavity defects may fracture while the sound-assumed wheel may not.
文摘The shrinkage defect of a ductile iron casting is attributed to the volume variations occurring in solidification, which consist of liquid contraction, solidification shrinkage, graphitization expansion, and mold cavity enlargement. Based on this understanding, a mathematical model for predicting the shrinkage defect of the casting is developed, in which the volume variations of the casting in soli- dification are numerically simulated, especially, the mold cavity enlargement is quantitatively calculated. Moreover, the reliability of the model is verified in production and experiment.
基金financially supported by the Program of National Technological Cooperation and Communication(Project 2010 DFR 70640)Chinese National S&T Major Project(2011ZX06004-016)
文摘Shrinkage cavities and large inclusions are serious internal defects of heavy steel ingot and influence the quality of subsequent forgings. In order to remove these two types of defects, a 70 t 12Cr2Mo1 heavy ingot fabricated by vacuum carbon de-oxidation process was sectioned and investigated by means of structure observation and EDS analysis. To further study the forming mechanism of shrinkage and inclusion defects and find possible solutions, simulation on pouring and solidification processes was also carried out using Fluent and ProCAST software, respectively. Results show that the shrinkage defects do not appear in the middle-upper part of the ingot. The critical value of shrinkage cavity criterion is ascertained as 0.013 on the basis of sectioning investigation and simulation results, which can be used in computer simulation to predict and avoid shrinkage defects in production of 12Cr2Mo1 ingots with different weights. However, large inclusions are found at the bottom of the ingot body. The bad thermal conditions of the ingot surface and large amount of entrained slag are the main origin of the large inclusions. The simulation result of the pouring process shows that large inclusions may be eliminated by combined measures of improving the top thermal condition and controlling the height of rudimental molten steel in the ladle to above 300 mm.
文摘Most of the shrinkage porosity criteria only consider internal thermal conditions, but ignore external conditions, such as pressure. Therefore, to some castings with a relatively high molten metal hydrostatic pressure or atmosphere pressure, the shrinkage porosity prediction will not be accurate enough. In order to solve this problem, this work studies and improves a known shrinkage porosity criterion ‘Xue Criterion’. The pressure is introduced into the criterion function and a relationship between ‘Xue Criterion’ and the pressure is established. The modified ‘Xue Criterion’ function can be expressed as p0Gτ/τ. Compared with the previous experimental work, the prediction result from the new shrinkage criterion has a good agreement with the experimental result, and it is more accurate than the original ‘Xue Criterion’.
基金supported by the National Natural Science Foundation of China(Grant No.51305350)the Basic Research Foundation of NWPU(No.3102014JCQ01045)
文摘Shrinkage porosity is a type of random distribution defects and exists in most large castings. Different from the periodic symmetry defects or certain distribution defects, shrinkage porosity presents a random "cloud-like" configuration, which brings difficulties in quantifying the effective performance of defected casting. In this paper, the influences of random shrinkage porosity on the equivalent elastic modulus of QT400-18 casting were studied by a numerical statistics approach. An improved random algorithm was applied into the lattice model to simulate the "cloud-like" morphology of shrinkage porosity. Then, a large number of numerical samples containing random levels of shrinkage were generated by the proposed algorithm. The stress concentration factor and equivalent elastic modulus of these numerical samples were calculated. Based on a statistical approach, the effects of shrinkage porosity's distribution characteristics, such as area fraction, shape, and relative location on the casting's equivalent mechanical properties were discussed respectively. It is shown that the approach with randomly distributed defects has better predictive capabilities than traditional methods. The following conclusions can be drawn from the statistical simulations:(1) the effective modulus decreases remarkably if the shrinkage porosity percent is greater than 1.5%;(2) the average Stress Concentration Factor(SCF) produced by shrinkage porosity is about 2.0;(3) the defect's length across the loading direction plays a more important role in the effective modulus than the length along the loading direction;(4) the surface defect perpendicular to loading direction reduces the mean modulus about 1.5% more than a defect of other position.
文摘针对基于显性知识的智能制造缺陷检测机制在工程实践中日益凸显的若干缺陷,提出了一种基于机器视觉和深度残差收缩网络(deep residual shrinkage networks,D-RSN)的智能制造缺陷检测方法,并进行了先验环境下的仿真验证。首先利用互补金属氧化物半导体(complementary metal oxide semiconductor,CMOS)相机集群搭建快速机器视觉图像获取装置,形成融合前置训练集和后置测试集的图像特征数据池;然后利用D-RSN对数据池前置训练集进行图像缺陷特征隐性知识学习辨识,构建时间正序下的图像缺陷特征全息感知机制;最后利用深度长短期记忆(deep long short-term memory,D-LSTM)神经网络对数据池后置测试集进行图像缺陷自主检测,借助图像缺陷定位及分类函数输出检测结果。选取某医用外科口罩智能制造生产线为工程实践验证载体,对模型进行了工程应用实践验证,结果表明:所提方法较好地改善了基于显性知识的智能制造缺陷检测机制在工程实践中日益凸显的若干缺陷,可以自主学习辨识图像缺陷特征隐性知识,大幅度提高了智能制造缺陷检测有效率,图像缺陷检测均值有效率达98.37%,符合医用外科口罩智能制造生产线国检要求。
基金National Natural Science Foundation of China (59975076, 50905144)State Key Laboratory of Materials Processing and Die & Mould Technology, Huazhong University of Science and Technology (09-10)+1 种基金NPU Foundation for Fundamental Research (JC201028)Fund of the State Key Laboratory of Solidification Process-ing in NWPU
文摘Thin-walled tube numerical control （NC） bending is a tri-nonlinear physical process with multi-defect and multi-die constraints. The clearance on each contact interface is the major factor to indicate the contact conditions. A three-dimensional-finite element （3D-FE） model is established to consider the realistic dynamic boundary conditions of multiple dies under ABAQUS/Explicit platform. Combined with experiment, numerical study on bending behavior and bendability under different clearance between tube and various dies is conducted in terms of wrinkling, wall thinning and cross section deformation. The results show that （1）with smaller clearance of tube-wiper die and tube-mandrel, the wrinkling can be restrained while the wall thinning It and cross-section deformation Id increase; while excessive small clearance blocks tube materials to flow past tangent point and causes piles up, the onset of wrinkling enhances It and Id. （2）Both It and Id decrease with smaller clearance of tube-pressure die; the wrinkling possibility rises with larger clearance on this interface if the mandrel’s freedom along Y-axis is opened; smaller clearance of tube-bend die prevents wrinkling while increases It, and the clearance on this interface has little effect on Id. （3）A modified Yoshida buckling test （YBT） is used to address the wrinkling mechanisms under normal constraints in tube bending： the smaller clearance may restrain wrinkling efficiently; the smaller wall thickness, the less critical clearance needed; the critical clearance for tube bending 38 mm×1 mm×57 mm （tube outer diameter×wall thickness×centerline bending radius） equals about 20% of initial wall thickness.
