CN107766651B - Casting residual stress release numerical simulation method - Google Patents
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Abstract
The invention provides a numerical simulation method for residual stress release of a casting, which relates to the field of mechanical manufacturing, establishes a finite element simulation model through UG, divides a mesh through HyperMesh, generates a mould shell and a casting cavity through ProCAST, numerically simulates a temperature field in the process of casting solidification and cooling, then leads out the casting, a ceramic core, the mould shell and other components in an ABAQUS receivable in an INP format, establishes a finite element simulation assembly model in the ABAQUS, and researches the residual stress release.
Description
Technical Field
The invention relates to the field of mechanical manufacturing, in particular to a method for simulating residual stress of a casting.
Background
The residual stress composition of a casting may be classified into thermal stress, phase transformation stress, and mechanical barrier stress according to the formation cause. The thermal stress and the phase change stress are mainly caused by the solidification processing technology and the characteristics of the material, and the mechanical barrier stress is caused by the constraint action of the mould shell and the ceramic core on the casting. The stress field distribution of the casting is difficult to study purely by a measuring mode, and the stress study of the casting needs to be numerically simulated by combining finite element software in consideration of the efficiency and the cost of the stress measurement of the casting. And when the conventional ProCAST software is adopted to simulate the stress field distribution in the casting solidification and cooling processes, the influence of the formwork and the ceramic core is not eliminated, and the residual stress distribution before the casting is demoulded is obtained through simulation, so that the simulation result is far from the experimental measurement value. Therefore, the stress field distribution of the casting is accurately researched by using a numerical simulation mode, and the process of removing the formwork and the ceramic core of the casting must be simulated firstly, so that the influence on the mechanical barrier stress of the casting is eliminated, and the residual stress of the casting is released.
Disclosure of Invention
Aiming at the problem that stress data has deviation due to different constraint states of simulation and actual measurement of a casting, the invention utilizes the advantages of ProCAST and ABAQUS, adopts a method of converting a temperature field of casting investment casting calculated by ProCAST and a unit file format and then guiding the converted temperature field and unit file format into ABAQUS, simulates to obtain a stress field before the casting is demoulded, and researches and simulates the casting shuttering and ceramic core removing process and the casting residual stress releasing process by using ABAQUS 'dead unit' technology and 'restart' technology, thereby solving the problem that the deviation of a numerical simulation result and experimental measurement data is large, and putting the invention into subsequent research and application.
The technical scheme adopted by the invention for solving the technical problem comprises the following steps:
step 1: UG establishes a casting pouring system model, wherein the casting pouring system comprises cold copper, a crystal selector, a crystal guide section, a casting and an inclined pouring channel, ProCAST software is used for carrying out numerical simulation on a temperature field in the solidification and cooling processes of the casting, post-processing software Visual-Viewer is used for exporting the temperature field of the casting, and then the Visual-Viewer application mode of the post-processing software is switched to the Mesh condition, so that inp model files of the casting, a mold shell, the cold copper and a ceramic core are respectively exported;
step 2: writing a ProCAST & ABAQUS temperature field conversion interface and a ProCAST & ABAQUS unit format conversion interface:
converting the casting temperature field obtained in the step 1 into an ABAQUS compatible temperature amplitude, a node set and a predefined field by using a temperature field conversion interface, namely deleting other contents except time history information in a log file of the casting temperature field file, storing the deleted contents as a text file in a text format, then introducing the text files in a text format ntl and a text file into a ProCAST and ABAQUS temperature field conversion interface to perform temperature field format conversion, and automatically storing the generated files in a text format;
converting the inp file of the formwork and the ceramic core obtained in the step 1 into a data format compatible with ABAQUS, namely, when the unit format of the formwork and the ceramic core is converted, because the information of four nodes forming each unit is contained in the inp unit file exported by ProCAST, before conversion, all the node information is deleted by using Emeditor software, only the unit information of each component is reserved and stored as a txt format file, and an import interface can be converted into the formwork and ceramic core unit file with the format required by ABAQUS;
and step 3: importing the casting, the formwork, the cold copper and the ceramic core inp model file exported in the step 1 into ABAQUS for assembly, setting a static steady state analysis step I, setting an amplitude set in the analysis step I, and keeping the boundary condition settings in the analysis step I consistent with ProCAST except for heat exchange conditions;
and 4, step 4: setting a static steady state analysis step two, setting a unit set, killing the unit set in the analysis step two by using a 'living and dead unit' technology, namely endowing a rigidity value to the unit, killing the unit lower than the rigidity value, setting a mass, damping and stress rigidity matrix of the killed unit to be 0, resetting the stress and strain of the unit to be 0 once the unit is killed, outputting a unit load vector of the killed unit to be zero, opening a restart analysis item in the analysis step two, and then exporting an obtained CAE data file in an x-inp format;
and 5: respectively copying the temperature amplitude value, the node set, the predefined field, the formwork and the ceramic core unit file with the converted format in the step 2 to corresponding positions of the inp file obtained in the step 3 and the step 4 to generate a new inp file;
step 6: for the new inp file generated in the step 5, operating by using an Abaqus Command line in a start menu to obtain the stress distribution when the formwork and the ceramic core of the casting are not removed;
and 7: and (3) establishing a new simulation Model by using an Abaqus Restart function, namely copying the Model in the step (1) to a new Model in ABAQUS, modifying and setting a Restart analysis in the new Model, establishing an analysis step III, taking the residual stress result of the casting obtained in the step (6) as an initial stress value in the analysis step III, and performing secondary simulation to obtain the stress release process of the casting.
The invention has the advantages that a finite element simulation model is established through UG, HyperMesh is used for dividing grids, ProCAST generates a mould shell and a casting cavity, numerical simulation is carried out on a temperature field in the process of casting solidification and cooling, then the casting, a ceramic core, the mould shell and other parts are led out in an ABAQUS acceptable form, a finite element simulation assembly model is established in the ABAQUS, and the research of residual stress release is carried out through a certain technical means.
Drawings
FIG. 1 is a flow chart of the practice of the present invention.
FIG. 2 is a casting gating system model of the present invention.
Fig. 3 is an interface diagram of ProCAST & ABAQUS temperature field conversion and unit format conversion interfaces of the present invention.
Fig. 4 is a graph showing the overall residual stress distribution before and after removing the mold shell and the ceramic core from the casting according to the present invention, wherein fig. 4(a) shows the stress distribution of the casting before removing the ceramic core and the mold shell, and fig. 4(b) shows the stress distribution of the casting after removing the ceramic core and the mold shell.
Fig. 5 is a graph of the residual stress relief process for a selected cell of the casting of the present invention, wherein [ X1E3 ] represents the power of 1000 to the third power of ten.
FIG. 6 is a comparison of experimental measured values and simulated values of residual stress at selected points of a section of a casting according to the present invention, where points represent the measured points.
Detailed Description
The invention is further illustrated with reference to the following figures and examples.
The embodiment is implemented on the premise of the technical scheme of the invention, and a detailed implementation mode and a process are given. The scope of the invention is not limited to the examples described below.
At present, the simulation prediction of the stress field distribution condition of a casting and further the product structure optimization are indispensable means, in the aspect of heat transfer analysis, the ProCAST can solve 3 heat transfer modes such as heat conduction, convection and radiation, and particularly, a latest 'ash body net radiation method' model is introduced, so that the ProCAST is good at solving the precision casting problem, and compared with the previous experiment, the ProCAST can very accurately simulate the temperature field of the casting process. Meanwhile, the ProCAST adopts a numerical calculation method based on a Finite Element Method (FEM), has higher flexibility, and is particularly suitable for simulating the forming process of complex castings. However, the formwork and the ceramic core have a great influence on the residual stress of the turbine blade, so that the formwork and the ceramic core must be removed in order to accurately obtain the stress field distribution of the blade, which cannot be realized in ProCAST. Therefore, only the temperature field in the blade casting process can be simulated by using ProCAST, and other simulation software is used for accurately simulating the blade stress release process after the formwork is removed and the ceramic core is removed. The unit can be killed and activated by the general large finite element analysis software ABAQUS, so that the removal of the formwork and the ceramic core can be realized. It is therefore conceivable to simulate the cooling process after solidification of the turbine blade using the ABAQUS software. The casting process of the turbine blade belongs to precision investment casting, covers the characteristics of vacuum environment, directional solidification, drawing speed and the like, and also relates to casting defects of shrinkage cavities, shrinkage porosity, inclusion and the like generated in the casting process of materials. These factors cannot be considered in ABAQUS, and it is difficult to accurately simulate the whole directional solidification process by using ABAQUS alone, so that the simulation of the three-dimensional residual stress release of the turbine blade is inaccurate, and a casting mold shell cannot be generated in ABAQUS, so that some contact constraint settings are performed.
Therefore, the results obtained by using ProCAST or ABAQUS alone to simulate the three-dimensional residual stresses of turbine blades during precision investment casting are not satisfactory. The two kinds of software have respective advantages, ProCAST has unique advantage in calculating the temperature field of the casting, and ABAQUS has incomparable advantage in removing the formwork and the ceramic core. Therefore, the invention creatively combines two finite element software aiming at the advantages and the disadvantages of the two kinds of software, and adopts the principle of advantage complementation to more accurately simulate the three-dimensional residual stress field of the single crystal turbine blade.
The stress release numerical simulation of a certain type of precision casting aircraft turbine blade is shown in the figure 1 by the implementation steps:
step 1: UG establishes a casting pouring system model, wherein the casting pouring system comprises cold copper, a crystal selector, a crystal guide section, a casting and an inclined pouring channel, ProCAST software is used for carrying out numerical simulation on a temperature field in the solidification and cooling processes of the casting, post-processing software Visual-Viewer is used for exporting the temperature field of the casting, and then the Visual-Viewer application mode of the post-processing software is switched to the Mesh condition, so that inp model files of the casting, a mold shell, the cold copper and a ceramic core are respectively exported;
the numerical simulation is carried out on a certain type of precision-cast turbine power blade, and the ProCAST software comprises the following contents in terms of numerical simulation of a turbine blade temperature field: modeling the whole gating system by using three-dimensional modeling software UG, as shown in figure 2, wherein the three-dimensional modeling software UG comprises a casting head, a transition section, turbine blades, a crystal selector, a cold copper plate, a blade core and a furnace body, the furnace body is a sheet body, and all components are led out in an iges format respectively; adopting commercial finite element pretreatment software Hypermesh to divide a model into units based on a non-uniform mesh subdivision technology, firstly respectively introducing the x, iges into the Hypermesh, dispersing the units into tetrahedral units, enabling the unit quality to meet the quality requirement of finite element analysis of a general enterprise, dividing each component into two-dimensional meshes, and respectively exporting the obtained components in a x, out format; respectively importing the obtained star-out files into ProCAST for assembly, grid quality inspection, generation of a formwork, body grid division and the like, and then giving materials to all components, wherein the turbine blade material is a high-temperature alloy DD6, and the thermal physical property and the mechanical parameters are all adopted [001 ]]The directional performance parameters are that the materials of the mould shell and the mould core are silica sand, the material of the cold copper material is pure copper, the other components except the casting are all set as rigid bodies, and the interface heat exchange coefficient of the casting and other components is 2000W/m2K, the heat transfer coefficient of the interface between the other components is 500W/m2K; in the boundary condition setting, the mold shell, the mold core and the cold copper are fixed, the external heat radiation rate of the outer surface of the whole mold shell is 0.85, the initial temperature of the cold copper is 20 ℃, the initial temperature of the casting, the mold shell and the mold core is 1550 ℃, and the gravity acceleration of the whole pouring system is 9.8m/s2Acceleration direction of [001]Direction; the furnace body is divided into three parts, wherein the temperature of the high temperature region is 1550 ℃, the radiance is 0.9, the temperature of the medium temperature region is 900 ℃, the radiance is 0.6, the temperature of the low temperature region is 20 ℃, the radiance is 0.5, the drawing speed of the whole furnace body is 0.8cm/min, and the drawing direction is [001 ]]Direction, then simulation can be carried out; after the ProCAST simulation is finished, casting temperature field files (including ntl and log files, wherein ntl stores casting temperature change history, and log files when stored in the Viewer-CAST post-processing softwareTime change process) and then switched to a Mesh mode, and the castings, the formworks and other components except the furnace body are respectively led out in an ABAQUS compatible x.
Step 2: writing a ProCAST & ABAQUS temperature field conversion interface and a ProCAST & ABAQUS unit format conversion interface:
converting the casting temperature field obtained in the step 1 into an ABAQUS compatible temperature amplitude, a node set and a predefined field by using a temperature field conversion interface, namely deleting other contents except time history information in a log file of the casting temperature field file, storing the deleted contents as a text file in a text format, then introducing the text files in a text format ntl and a text file into a ProCAST and ABAQUS temperature field conversion interface to perform temperature field format conversion, and automatically storing the generated files in a text format;
converting the inp file of the formwork and the ceramic core obtained in the step 1 into a data format compatible with ABAQUS, namely, when the unit format of the formwork and the ceramic core is converted, because the information of four nodes forming each unit is contained in the inp unit file exported by ProCAST, before conversion, all the node information is deleted by using Emeditor software, only the unit information of each component is reserved and stored as a txt format file, and an import interface can be converted into the formwork and ceramic core unit file with the format required by ABAQUS;
as shown in fig. 3, the ProCAST & ABAQUS temperature field conversion interface and ProCAST & ABAQUS unit format conversion interface obtained by VC + +6.0 programming are used to convert the turbine blade temperature field derived in step 1 and the formats of the component units, so as to obtain a txt file of the temperature field and the unit format compatible with ABAQUS. When the format conversion of the temperature field is carried out, other contents except the time history information in the log file need to be deleted and stored as a file in the txt format, then the format conversion of the temperature field can be carried out by utilizing the ntl and the txt file import interface, and all the generated files are automatically stored in the txt format. When the form conversion of the formwork and the ceramic unit is carried out, because the information of four nodes forming each unit is contained in the inp unit file exported by ProCAST, before the conversion, all the node information needs to be deleted by using Emeditor software, only the unit information of each component is reserved and stored as the txt form file, and the import interface can be converted into the formwork and the ceramic unit file with the form required by ABAQUS.
And step 3: importing the casting, the formwork, the cold copper and the ceramic core inp model file exported in the step 1 into ABAQUS for assembly, setting a static steady state analysis step I, setting an amplitude set in the analysis step I, and keeping the boundary condition settings in the analysis step I consistent with ProCAST except for heat exchange conditions;
respectively importing the tip file of the turbine blade, the die shell, the ceramic core and other components exported in the step 1 into ABAQUS for assembly, exporting various material parameter data of the DD6 material from ProCAST in a material attribute module, importing the data into ABAQUS after unit conversion, selecting the DD6 single crystal material after unit conversion for the turbine blade, and setting the die shell, the die core and the cold copper material according to the parameters in ProCAST. Setting a static steady-state analysis step I, wherein the boundary conditions in the other analysis steps I are set to be consistent with those of ProCAST except for heat exchange conditions, wherein each contact pair is selected by adopting a method for finding the contact pair, and the method needs to be explained as follows: at this time, an amplitude Set needs to be established for a certain node of the leaf in the analysis step one under the load module, and the amplitude Set is recorded as Set-1.
And 4, step 4: setting a static steady state analysis step II, setting a unit set, killing the unit set in the analysis step II by using a 'living and dead unit' technology, namely endowing a rigidity value to the unit, killing the unit lower than the rigidity value, setting a mass, damping and stress rigidity matrix of the killed unit to be 0, resetting the stress and strain of the unit to be 0 once the unit is killed, and outputting a unit load vector of the killed unit to be zero, wherein the rigidity value is 10E-6, opening a restart analysis item in the analysis step II, and then exporting an obtained CAE data file in a star-inp format;
after the parameters of the analysis Step one in the Step 3 are Set, a static steady-state analysis Step two is Set, a unit Set is Set in a selected turbine blade part region unit and is marked as Set-2, a 'death unit' technology is used in the analysis Step two to kill the unit Set, a Restart item needs to be Set in the analysis Step two, the specific setting method is that Restart Requests in Output are opened under a Step module, the analysis Step two is selected, and then the obtained CAE data file is exported in a star-inp format.
And 5: respectively copying the temperature amplitude value, the node set, the predefined field, the formwork and the ceramic core unit file with the converted format in the step 2 to corresponding positions of the inp file obtained in the step 3 and the step 4 to generate a new inp file;
and copying and pasting the temperature amplitude, the node Set and the predefined field which are subjected to format conversion in the step 2 to a position of an amplitude Set-1 in a data file, replacing the amplitude data which is Set before, copying and pasting the formwork and the ceramic core unit file which are subjected to format conversion in the step 2 to a position of a unit Set-2 in the data file, replacing the unit number which is Set before, and generating and storing a new simulation file of the x, inp.
Step 6: for the new inp file generated in the step 5, operating by using an Abaqus Command line in a start menu to obtain the stress distribution when the formwork and the ceramic core of the casting are not removed;
for the new inp file generated in step 5, which is run using the Abaqus Command line in the start menu, as shown in fig. 4, to find the stress distribution when the turbine blade is not removing the form and ceramic core, the inp file must be placed in the Temp entry of the Abaqus installation directory before it can be called.
And 7: and (3) creating a new simulation Model by using an Abaqus Restart function, namely copying the Model in the step (1) to a new Model in ABAQUS, modifying and setting a Restart analysis in the new Model, establishing an analysis step III, taking the residual stress result of the casting obtained in the step (6) as an initial stress value in the analysis step III, and performing secondary simulation to obtain a casting stress release process, wherein the process is shown in a figure 4 and a figure 5.
The specific method comprises the following steps: in ABAQUS, the original Model is copied to a new Model, and then the modification and setting of Restart analysis are performed in the new Model. The settings of the Model for restarting the analysis before starting the analysis step or incremental step of Restart analysis must be consistent with the original Model settings, with the following constraints: (1) the geometry cannot be modified or added; (2) any previously set step or boundary conditions cannot be modified. Therefore, in order to observe the change process of the stress of the casting after the formwork and the ceramic core are removed by the aid of a restarting technology, the formwork and the ceramic core are removed in the step of initial modeling, and then the formwork and the ceramic core are removed by restarting the model copied in analysis. Since only a Step can be newly built and a new Load can be added during restarting, a Step-2 with very short analysis time must be built in the Step 3, which is to inherit the blade stress distribution obtained by simulation when the formwork and the ceramic core are not removed as the initial stress of the Step-3 to carry out stress release numerical simulation. The above is a specific implementation process of this embodiment.
FIG. 6 is a graph comparing stress results from a numerical simulation of stress relief for an exemplary turbine blade with experimentally measured data, as can be seen in FIG. 6: the turbine blade stress value after the stress is released is very consistent with the measured value, which shows that the invention is reliable and credible, and has great practical value for accurately predicting the residual stress distribution condition of the casting.
Claims (1)
1. A casting residual stress release numerical simulation method is characterized by comprising the following steps:
step 1: UG establishes a casting pouring system model, wherein the casting pouring system comprises cold copper, a crystal selector, a crystal guide section, a casting and an inclined pouring channel, ProCAST software is used for carrying out numerical simulation on a temperature field in the solidification and cooling processes of the casting, post-processing software Visual-Viewer is used for exporting the temperature field of the casting, and then the Visual-Viewer application mode of the post-processing software is switched to the Mesh condition, so that inp model files of the casting, a mold shell, the cold copper and a ceramic core are respectively exported;
step 2: writing a ProCAST & ABAQUS temperature field conversion interface and a ProCAST & ABAQUS unit format conversion interface:
converting the casting temperature field obtained in the step 1 into an ABAQUS compatible temperature amplitude, a node set and a predefined field by using a temperature field conversion interface, namely deleting other contents except time course information in a log file of the casting temperature field file, storing the deleted contents as a txt format file, then introducing a StarST ntl and a txt file of the casting temperature field file into a ProCAST and ABAQUS temperature field conversion interface for temperature field format conversion, and automatically storing the generated files into a txt format;
converting the inp file of the formwork and the ceramic core obtained in the step 1 into a data format compatible with ABAQUS, namely, when the unit format of the formwork and the ceramic core is converted, because the information of four nodes forming each unit is contained in the inp unit file exported by ProCAST, before conversion, all the node information is deleted by using Emeditor software, only the unit information of each component is reserved and stored as a txt format file, and an import interface can be converted into the formwork and ceramic core unit file with the format required by ABAQUS;
and step 3: importing the casting, the formwork, the cold copper and the ceramic core inp model file exported in the step 1 into ABAQUS for assembly, setting a static steady state analysis step I, setting an amplitude set in the analysis step I, and keeping the boundary condition settings in the analysis step I consistent with ProCAST except for heat exchange conditions;
and 4, step 4: setting a static steady state analysis step two, setting a unit set, killing the unit set in the analysis step two by using a 'living and dead unit' technology, namely endowing a rigidity value to the unit, killing the unit lower than the rigidity value, setting a mass, damping and stress rigidity matrix of the killed unit to be 0, resetting the stress and strain of the unit to be 0 once the unit is killed, outputting a unit load vector of the killed unit to be zero, opening a restart analysis item in the analysis step two, and then exporting an obtained CAE data file in an x-inp format;
and 5: respectively copying the temperature amplitude, the node set, the predefined field, the formwork and the ceramic core unit files with the converted formats in the step 2 to corresponding positions of the inp file obtained in the step 4 to generate a new inp file;
step 6: for the new inp file generated in the step 5, operating by using an Abaqus Command line in a start menu to obtain the stress distribution when the formwork and the ceramic core of the casting are not removed;
and 7: and (3) establishing a new simulation Model by utilizing an Abaqus Restart function, namely copying the Model in the step (1) to a new Model in ABAQUS, modifying and setting a Restart analysis in the new Model, establishing an analysis step III, taking the residual stress result of the casting obtained in the step (6) as an initial stress value in the analysis step III, performing secondary simulation, namely removing the formwork and the ceramic core, and obtaining the stress distribution after the formwork and the ceramic core are removed.
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN110111861B (en) * | 2019-05-24 | 2020-12-22 | 上海交通大学 | Prediction method for thermal cracks in solidification process of magnesium and aluminum alloy castings |
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