【作者】 郭善海；

【导师】 胡树根； 宋小文； 黄长林；

【作者基本信息】 浙江大学 ， 机械设计及理论， 2006， 硕士

【摘要】 当前，铸件充型凝固过程数值模拟是最具竞争力的铸造工艺研究方法。通过充型凝固过程的数值模拟，可以预测铸造缺陷，优化铸造工艺参数，确保铸件质量，缩短试制周期，降低生产成本。 随着CAD／CAE软件的不断发展，越来越多的公司将其应用到企业中，指导实际生产。本文的工作与宁波东电电力设备有限公司合作进行，以Solid Edge软件为前处理平台，以ProCAST软件为模拟平台，展开了如下的研究工作： Solid Edge与ProCAST间复杂模型的数据转换一直存在问题，成为进行数值模拟的障碍。因此，本文首先针对两款软件的接口方式进行研究，寻求有效的方案解决前处理过程中复杂模型的数据交换问题。 结合工厂实际生产的需要，对拖车连杆头铸件进行数值模拟，并将模拟结果与试制结果作比较，在充分肯定ProCAST软件分析准确性的基础上，从浇注系统和补缩系统入手，对铸件进行工艺参数的优化设计。 对于KU—1004密封壳体铸件，企业提出了两种不同的浇注工艺方案。将顶注工艺和底注工艺的充型过程和凝固过程进行模拟，并将模拟结果进行对比分析，从中选出最优的工艺，为实际生产提供科学的依据和指导。 本文首次对Solid Edge与ProCAST间的数据交换进行研究，提出体包含的概念，采用总—分—总的技术路线，有效的解决了前处理中复杂模型的数据交换难题。优化后的浇冒口一体化的顶注工艺避免了原工艺中产生的缺陷，得到了高质量的铸件，该工艺在工厂中已得到了实际应用。工艺优选的依据为工厂中生产类似铸件时确定工艺参数提供了科学的指导。实践证明，采用数值模拟软件，能够快速、有效的解决工艺问题，为企业带来巨大的经济效益，具有重要的实用价值和现实意义。更多还原

【Abstract】 At present, the most competitive research method of foundry technology is numerical simulation on mold filling and solidification process. This process is helpful to predict defects, optimize technologic parameters, insure the casting quality, shorten the trial-produce cycle and lower the cost.With the development of CAD/CAE software, more and more companies apply them to production process. Co-operating with Ningbo Dongdian Electric Power Equipment CO., LTD, this paper, based on Solid Edge and ProCAST, does the research work as follows:There is a data transform problem between Solid Edge and ProCAST software, which is an obstacle to the numerical simulation. One of the research is to find a valid mode to solve this problem.According to the real needs of the company, the process of numerical simulation on trailer big end is conducted. The results prove the parameters are correct through comparing with the trial product. Then the technology is optimized from gating and feeding system.Top and bottom gating system of KU-1004 casting, which are provided by the company, are simulated in this paper. Their competitive results, which can be as the reference and gist, show which one is better and where needs to be optimized.This paper puts forward the model-containing concept for the first time and resolves the data transform problem of complex models between Solid Edge and ProCAST by using a technical way of "whole - parted - whole". Optimized technology avoids generating defects in the casting body and has been applied in the company. The gist of selecting technology helps to establish the parameters of similar castings. It is proved that numerical simulation can solve technologic problem and create huge economy benefits, which means a lot to the company.更多还原