CN109865800B - Simulation analysis method for heating and curing process of precoated sand of hot core box - Google Patents
Simulation analysis method for heating and curing process of precoated sand of hot core box Download PDFInfo
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- 238000010438 heat treatment Methods 0.000 title claims abstract description 57
- 238000004088 simulation Methods 0.000 title claims abstract description 54
- 238000000034 method Methods 0.000 title claims abstract description 29
- 238000004458 analytical method Methods 0.000 title claims abstract description 27
- 230000008569 process Effects 0.000 title claims abstract description 23
- 239000004576 sand Substances 0.000 title claims abstract description 21
- 238000004364 calculation method Methods 0.000 claims abstract description 38
- 238000013499 data model Methods 0.000 claims abstract description 29
- 238000005266 casting Methods 0.000 claims abstract description 23
- 239000000463 material Substances 0.000 claims abstract description 8
- 238000010926 purge Methods 0.000 claims abstract description 5
- 238000005259 measurement Methods 0.000 claims description 19
- 238000004519 manufacturing process Methods 0.000 claims description 5
- 230000005484 gravity Effects 0.000 claims description 4
- 229910001018 Cast iron Inorganic materials 0.000 claims description 3
- 238000012937 correction Methods 0.000 description 6
- 238000010586 diagram Methods 0.000 description 4
- 230000006872 improvement Effects 0.000 description 4
- 230000036757 core body temperature Effects 0.000 description 3
- 238000013461 design Methods 0.000 description 3
- 238000005457 optimization Methods 0.000 description 3
- YLQBMQCUIZJEEH-UHFFFAOYSA-N Furan Chemical compound C=1C=COC=1 YLQBMQCUIZJEEH-UHFFFAOYSA-N 0.000 description 2
- 238000001514 detection method Methods 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- 229910000838 Al alloy Inorganic materials 0.000 description 1
- 238000009529 body temperature measurement Methods 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
- 238000007711 solidification Methods 0.000 description 1
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Abstract
The invention relates to a simulation analysis method for a heating and curing process of precoated sand of a hot core box, which comprises the following steps: step one, preparing a data model; step two, importing the data model in the step one into casting simulation software, and setting material properties of a sand core mould, a sand core body, a heating pipe and a virtual casting; setting position coordinates of the thermocouple; fourthly, carrying out finite difference grid division on the data model; setting parameters, setting initial temperatures of the sand core mold, the sand core body, the heating pipe and the virtual casting, and setting interface heat exchange coefficients, heat cycle times, mold opening and closing time, purging time and opening and closing conditions of the heating pipe; and sixthly, obtaining the temperature field data of the sand core mould and the temperature field data of the sand core body through simulation calculation. The method has the advantages that the existing casting simulation software is used for simulating the heating and curing process of the precoated sand of the hot core box, no additional sand shooting analysis module is needed, and the cost is reduced.
Description
Technical Field
The invention relates to numerical simulation of a casting process, in particular to a simulation analysis method for a heating and curing process of precoated sand of a hot core box.
Background
The quality of the heating and curing process of the precoated sand of the hot core box is one of the most main influence factors influencing the performance indexes of the sand core such as forming strength, gas forming amount, collapsibility and the like. Whether the heating and curing process is good or bad is judged, and whether the temperature distribution in the heating process is uniform or not, namely whether the power and the arrangement of a heating pipe in the die are reasonable or not is mainly judged. Traditional process designers mainly rely on experience to select and arrange heating pipes, and with the development of computer aided engineering, more and more casting enterprises begin to guide casting process design by means of simulation technology, so that the number of die testing times is reduced, and the cost is reduced. At present, the sand core heating curing simulation software is less, only a Magmasoft sand shooting analysis module can be realized in China, but the cost is higher, the utilization rate is lower, and the cost performance is low.
Disclosure of Invention
The invention aims to provide a simulation analysis method for a heating and curing process of precoated sand of a hot core box.
The invention relates to a simulation analysis method for a heating and curing process of precoated sand of a hot core box, which comprises the following steps:
preparing a data model, wherein the data model comprises a sand core mould, a sand core body, a heating pipe and a virtual casting;
step two, importing the data model in the step one into casting simulation software, and setting material properties of a sand core mould, a sand core body, a heating pipe and a virtual casting;
setting the position coordinates of the thermocouple according to the position of the temperature control thermocouple of the actual mold;
fourthly, carrying out finite difference grid division on the data model;
step five, setting parameters according to the production process of an actual mould, setting initial temperatures of the sand core mould, the sand core body, the heating pipe and the virtual casting, and setting interface heat exchange coefficients, heat cycle times, mould opening and closing time, purging time and heating pipe opening and closing conditions;
and sixthly, obtaining the temperature field data of the sand core mould and the temperature field data of the sand core body through simulation calculation.
Further, still include: and step seven, obtaining temperature field data of the sand core mold and temperature field data of the sand core body at the mold opening time through simulation calculation to form a simulation calculation result, acquiring the temperature field data of the sand core mold and the temperature field data of the sand core body at the actual mold opening time of the mold to form an actual measurement result, calibrating the simulation calculation result in the step six according to the actual measurement result, and correcting the simulation calculation result by adjusting the opening and closing conditions of the heating pipe until the error of the simulation calculation result is not more than 20 ℃.
Further, the virtual casting in the step one is positioned on the outer side of the sand core mold, and the distance between the virtual casting and the sand core mold is not less than 150 mm.
Further, the casting simulation software adopted in the second step is Magmasoft.
Furthermore, the grid at the position of the minimum wall thickness of the data model in the fourth step is not less than 3 layers.
Further, in the second step, the data model in the first step is imported into a gravity casting analysis module or a low-pressure casting analysis module or a cast iron casting analysis module of casting simulation software.
The method has the advantages that the existing casting simulation software is utilized to simulate the heating and curing process of the precoated sand of the hot core box, no additional sand shooting analysis module is required to be purchased, and the cost is reduced; the analysis precision is high, and the method has guiding significance on the design of the sand shooting process; the cost is saved and is high, the power optimization and the arrangement optimization of the heating pipes of the sand core die can be guided, the die testing times can be reduced, and the production cost can be reduced.
Drawings
FIG. 1 is a data model in an embodiment;
FIG. 2 is a mesh sectional view of a data model in an embodiment;
FIG. 3 is a temperature field data diagram of the sand core body at the moment the data model is opened;
FIG. 4 is a graph of temperature field data for a sand core body at the actual mold opening time in the example;
FIG. 5 is a graph comparing the simulation calculation result and the actual measurement result of the temperature field data of the sand core body at the time of mold opening in the embodiment;
FIG. 6 is a temperature field data diagram of the sand core body at the time of opening the data model after correction in the example;
FIG. 7 is a comparison graph of the simulated calculation results and the actual measurement results of the temperature field data of the sand core body after correction in the embodiment;
FIG. 8 is a temperature field data diagram of the lower mold of the sand core at the time of opening the data model after correction in the embodiment;
FIG. 9 is a temperature field data diagram of the lower mold of the sand core at the actual mold opening time in the example;
FIG. 10 is a graph comparing the results of simulation and actual measurement of temperature field data for a lower mold of a sand core at the time of mold opening in the examples.
In the figure: 1-sand core upper mould; 2, a sand core lower die; 3-an upper die heating pipe; 4-lower die heating pipe; 5, a sand core body; 6-virtual casting.
Detailed Description
The invention will be further explained with reference to the drawings.
A simulation analysis method for a heating and curing process of precoated sand of a hot core box comprises the following steps:
preparing a data model, wherein the data model comprises a sand core mould, a sand core body, a heating pipe and a virtual casting;
step two, importing the data model in the step one into casting simulation software, and setting material properties of a sand core mould, a sand core body, a heating pipe and a virtual casting;
setting the position coordinates of the thermocouple according to the position of the temperature control thermocouple of the actual mold;
fourthly, carrying out finite difference grid division on the data model;
step five, setting parameters according to the production process of an actual mould, setting initial temperatures of the sand core mould, the sand core body, the heating pipe and the virtual casting, and setting interface heat exchange coefficients, heat cycle times, mould opening and closing time, purging time and heating pipe opening and closing conditions;
and sixthly, obtaining the temperature field data of the sand core mould and the temperature field data of the sand core body through simulation calculation. The temperature field data of the sand core die and the temperature field data of the sand core body can guide process designers to optimize the sand core process.
As an improvement, the method further comprises the following steps: and step seven, obtaining temperature field data of the sand core mold and temperature field data of the sand core body at the mold opening time through simulation calculation to form a simulation calculation result, acquiring the temperature field data of the sand core mold and the temperature field data of the sand core body at the actual mold opening time of the mold to form an actual measurement result, calibrating the simulation calculation result in the step six according to the actual measurement result, and correcting the simulation calculation result by adjusting the opening and closing conditions of the heating pipe until the error of the simulation calculation result is not more than 20 ℃. Through calibration and correction, the simulation calculation result has more practical value.
As an improvement, the virtual casting in the first step is positioned at the outer side of the sand core mold, and the distance between the virtual casting and the sand core mold is not less than 150 mm. The virtual casting is guaranteed not to interfere with the temperature field of the sand core solidification model.
As a modification, the casting simulation software adopted in the second step is Magmasoft.
As an improvement, the grid at the position of the minimum wall thickness of the data model in the fourth step is not less than 3 layers.
As an improvement, in the second step, the data model in the first step is imported into a gravity casting analysis module or a low-pressure casting analysis module or a cast iron casting analysis module of casting simulation software. And an additional sand shooting analysis module is not required to be purchased, so that the cost is reduced.
The simulation analysis process for a certain actual mold is as follows:
step one, preparing a data model, as shown in fig. 1, wherein the data model comprises an upper sand core mould 1, a lower sand core mould 2, an upper mould heating pipe 3, a lower mould heating pipe 4, a sand core body 5 and a virtual casting 6, and the virtual casting 6 is a cube of 10 mm.
Step two, opening an aluminum alloy gravity casting module of Magmasoft, guiding data models of an upper sand core mould 1, a lower sand core mould 2, an upper mould heating pipe 3, a lower mould heating pipe 4, a sand core body 5 and a virtual casting 6 into the Magmasoft, setting the materials of the upper sand core mould 1 and the lower sand core mould 2 as X38CrMoV5_1, setting the materials of the upper mould heating pipe 3 and the lower mould heating pipe 4 as TempCart _ NiCr8020, setting the material of the sand core body 5 as Furan, and setting the material of the virtual casting 6 as AlSi6Cu 4;
setting thermocouple position coordinates according to the actual mold temperature control thermocouple position, wherein the thermocouples comprise an upper mold thermocouple and a lower mold thermocouple;
step four, as shown in fig. 2, finite difference grid division is carried out on the data model;
step five, setting simulation parameters according to the production process of the actual die, wherein the simulation parameters are set as follows:
1) initial conditions: setting the initial temperature of an upper sand core mould 1 and a lower sand core mould 2 to be 230 ℃, setting the working temperature of an upper mould heating pipe 3 and a lower mould heating pipe 4 to be 400 ℃, setting the initial temperature of a sand core body 5 to be 20 ℃, and setting the initial temperature of a virtual casting 6 to be 700 ℃;
2) boundary conditions: setting the heat exchange coefficient of the interface of the mould and the mould as 2000W/(m ^2 ^ K), setting the heat exchange coefficient of the interface of the mould and the sand core as 300W/(m ^2 ^ K), and setting the heat exchange coefficient of the interface of the mould and the heating pipe as 1500W/(m ^2 ^ K);
3) the process time is as follows: simulating 15 thermal cycles in total, keeping the mold for heating and curing for 90s, opening the mold, taking a workpiece for cleaning for 35s, and purging for 5 s;
4) temperature control: when the upper die thermocouple detects that the temperature is lower than 221 ℃, the upper die heating pipe 3 is opened, and when the upper die thermocouple detects that the temperature is higher than 225 ℃, the upper die heating pipe 3 is closed; when the lower mold thermocouple detects that the temperature is lower than 232 ℃, the lower mold heating pipe 4 is opened, and when the lower mold thermocouple detects that the temperature is higher than 244 ℃, the lower mold heating pipe 4 is closed. It should be understood that this temperature control range is only collected by the field device, but due to the errors caused by the thermocouple temperature measurement delay, the simulation model not including the peripheral attachment mechanism devices of the mold, etc., the temperature control range should be corrected during the subsequent temperature calibration.
And step six, obtaining the temperature field data of the sand core body at the mold opening time and the temperature field data of the sand core mold through simulation calculation so as to obtain a simulation calculation result, and obtaining the simulation calculation result of the temperature field data of the sand core body at the mold opening time as shown in fig. 3.
Step seven, shooting by using a thermal imager to obtain temperature field data of the sand core mold and temperature field data of the sand core body at the actual mold opening time so as to obtain an actual measurement result, obtaining an actual measurement result of the temperature field data of the sand core body at the mold opening time as shown in fig. 4, calibrating a simulation calculation result by using the actual measurement result, selecting 10 data points in the sand core body, comparing temperature values to obtain a comparison graph of the simulation calculation result and the actual measurement result of the temperature field data of the sand core body at the mold opening time as shown in fig. 5, obtaining the temperature field value of the simulation calculation result by parameter analysis to be lower than the temperature field value of the actual measurement result, and properly increasing the temperature control range of the upper mold thermocouple due to the contact of the data point area with the upper mold (when the detection temperature of the upper mold thermocouple is lower than 230 ℃, the upper mold heating pipe 3 is opened, when the detection temperature, closing the upper die heating pipe 3), and obtaining a simulation calculation result of the corrected sand core body temperature field data at the die opening time as shown in fig. 6 after re-simulation calculation; further, a comparison graph of the simulation calculation result of the corrected die-opening time sand core body temperature field data and the actual measurement result as shown in fig. 7 is obtained, and the average error of the absolute value of the simulation calculation result of the corrected die-opening time sand core body temperature field data relative to the actual measurement result is calculated to be reduced from 45.8 ℃ before correction to 16.9 ℃ after correction. Calibrating the temperature field data of the lower sand core mould continuously by using the corrected parameters, obtaining a simulation calculation result of the temperature field data of the lower sand core mould at the mould opening time as shown in figure 8 through simulation calculation, and obtaining an actual measurement result of the temperature field data of the lower sand core mould at the mould opening time as shown in figure 9 through shooting by a thermal imager; and 9 data points are selected on the sand core lower die, the temperature values are compared, a comparison graph of the simulation calculation result and the actual measurement result of the sand core lower die temperature field data at the corrected die opening time shown in the graph 10 can be obtained, and the average error of the simulation calculation result of the sand core lower die temperature field data relative to the absolute value of the actual measurement result is only 9.2 ℃ through calculation. After the simulation calculation result is calibrated, the temperature error range of the sand core body or the mould obtained by simulation is within an acceptable range, the analysis precision is high, the method has guiding significance on the sand shooting process design, and can be applied to the actual guidance of the optimization of the precoated sand heating and curing process of the hot core box. Because the shooting temperature value of the thermal imager is influenced by factors such as distance, angle, surface roughness and the like, one side close to the thermal imager should be selected as far as possible when the point on the approximately symmetrical structure on the mold or the sand core is used for calibrating the temperature.
Claims (4)
1. A simulation analysis method for a heating and curing process of precoated sand of a hot core box is characterized by comprising the following steps:
preparing a data model, wherein the data model comprises a sand core mould, a sand core body, a heating pipe and a virtual casting;
step two, importing the data model in the step one into a gravity casting analysis module or a low-pressure casting analysis module or a cast iron casting analysis module of casting simulation software Magmasoft, and setting the material properties of a sand core mould, a sand core body, a heating pipe and a virtual casting;
setting the position coordinates of the thermocouple according to the position of the temperature control thermocouple of the actual mold;
fourthly, carrying out finite difference grid division on the data model;
step five, setting parameters according to the production process of an actual mould, setting initial temperatures of the sand core mould, the sand core body, the heating pipe and the virtual casting, and setting interface heat exchange coefficients, heat cycle times, mould opening and closing time, purging time and heating pipe opening and closing conditions;
and sixthly, obtaining the temperature field data of the sand core mould and the temperature field data of the sand core body through simulation calculation.
2. The method for simulating and analyzing the heating and curing process of the hot-box precoated sand according to claim 1, further comprising: and step seven, obtaining temperature field data of the sand core mold and temperature field data of the sand core body at the mold opening time through simulation calculation to form a simulation calculation result, acquiring the temperature field data of the sand core mold and the temperature field data of the sand core body at the actual mold opening time of the mold to form an actual measurement result, calibrating the simulation calculation result in the step six according to the actual measurement result, and correcting the simulation calculation result by adjusting the opening and closing conditions of the heating pipe until the error of the simulation calculation result is not more than 20 ℃.
3. The simulation analysis method for the heating and curing process of the hot-box precoated sand according to claim 1, characterized in that: the virtual casting in the step one is positioned on the outer side of the sand core mould, and the distance between the virtual casting and the sand core mould is not less than 150 mm.
4. The simulation analysis method for the heating and curing process of the hot-box precoated sand according to claim 1, characterized in that: and in the fourth step, the grid at the position of the minimum wall thickness of the data model is not less than 3 layers.
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