CN110232241B - Hemispherical fusion-cast explosive casting process simulation method - Google Patents
Hemispherical fusion-cast explosive casting process simulation method Download PDFInfo
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Abstract
A hemispherical fusion-cast explosive casting process simulation method comprises the following steps: geometric modeling is carried out in step 10, grid division is carried out in step 20, preprocessing is carried out in step 30, and solving calculation and result analysis are carried out in step 40. The method is suitable for process design and model test of various hemispherical fusion casting explosives in the casting process, takes the sphere diameter as a key control parameter for geometric modeling, and can be flexibly adjusted by combining with actual working conditions. The method has high transportability and good repeatability.
Description
Technical Field
The invention belongs to the field of casting processes of fusion-cast explosives, and particularly relates to a simulation method of a hemispherical fusion-cast explosive casting process.
Background
Fusion cast explosives are a very important class of military hybrid explosives. The mature and stable process is a great advantage and characteristic of the preparation of the fusion cast explosive. A plurality of manual participation links exist in the preparation process of the fusion cast explosive, so that the design level is low. In the actual production process, various types of fusion-cast explosives are often required to be prepared into hemispherical raw materials for subsequent links. Most of the time, the preparation process of the hemispherical fusion cast explosive only stays at the completion level, the process design is lacked, the law of the influence factors on the product quality is not known, and a corresponding simulation design method is urgently needed to be established.
Chinese patent CN201611105149.1 discloses a blade casting method, which adopts a CAD design system to design a casting mold of an engine blade. However, the method is only suitable for aluminum alloy products, is not suitable for the preparation process of the hemispherical fusion cast explosive, and lacks a corresponding simulation design method.
Therefore, the simulation virtual design of the hemispherical fusion-cast explosive casting process needs to be strengthened, and technical support is provided for practical application.
Disclosure of Invention
Aiming at the defects in the prior art, the invention provides a method for simulating the casting process of a hemispherical cast explosive, and provides a method for designing the casting process of various hemispherical cast explosives.
In order to achieve the above object, the present invention adopts the following technical solutions:
the invention relates to a method for simulating a casting process of a hemispherical fusion cast explosive, which is characterized by comprising the following steps of:
step 10, calculating a model in the casting process of the hemispherical fusion-cast explosive, wherein the model comprises a hemispherical casting, a hemispherical bottom die, a frame and a base; firstly, adopting ANSYS design nModelr software to construct a geometric model of a hemispherical casting in a mode of designating a sphere diameter, storing the geometric model as a geometric file with a suffix file name of an igs format, then continuously using GeoMesh software to reopen the geometric file with the saved igs format, trimming a geometric figure, and storing the geometric file as a geometric file with a suffix file name of an iges format, so as to complete the construction work of the geometric model of the hemispherical casting; repeating the steps to complete the construction work of the geometric models of the hemispherical bottom die, the frame and the base in sequence.
And 20, importing the geometric models of the four components of the hemispherical casting, the hemispherical bottom die, the frame and the base, which are constructed in the step 10, into a ProCAST software visual mesh meshing component, checking the Boolean relationship of the geometric graph relationship of the four components, trimming redundant and overlapped parts, assembling and integrating the components to form a structural model for simulation calculation, controlling the mesh quality by a method of randomly generating seeds, and meshing the structural model by adopting unstructured tetrahedral meshes to form uniform and smooth calculation meshes.
Step 30, starting the VisualCast pretreatment assembly on the basis of the step 20, selecting a gravity casting mode as a casting mode, setting the hemispherical casting to be a fusion-cast explosive material type, setting initial conditions to be a metal material type, wherein the initial conditions comprise a casting speed of 0.2-1.5 m/s and a casting temperature of 82-123 ℃, setting the hemispherical bottom die, the hemispherical frame and the base to be a metal material type, the initial conditions comprise an initial temperature of 20-65 ℃ and a filling proportion fraction of 1.0, selecting an interface mode between the hemispherical casting and the hemispherical bottom die to be a consistency non-common node type, setting a boundary condition type to be an interface heat exchange type, and setting a heat exchange coefficient to be 500 W.m -2 ·K -1 ～1000W·m -2 ·K -1 And modifying part of the calculation parameters by taking the predefined gravity casting mode operation parameters as a reference to form a user-defined calculation parameter file, and simultaneously storing a data file and a calculation parameter file.
And step 40, taking the data file and the calculation parameter file saved in the step 30 as the basis, calling a flow analysis and thermal analysis solver to calculate the casting process of the hemispherical cast explosive, accelerating the calculation process by using a multi-core technology, automatically outputting a result file after the calculation is finished, and extracting the results of a flow field and a temperature field by using a VisualViewer visual component to finish the simulation of the casting process of the hemispherical cast explosive.
Further, in step 10, the sphere diameter ranges from 20mm to 100mm.
Further, in the step 10, the ANSYS design model software is adopted to carry out flexible design of the geometric model according to actual working conditions.
Further, in step 10, the geometry is trimmed by using GeoMesh software, so that the read compatibility of the geometry data can be improved.
Further, in step 20, the grid quality specifically includes: the maximum value of the torsion resistance is not more than 30, and the minimum value of the Jacobian is not less than 0.7. The adoption of the high-quality computing grid is beneficial to improving the computing precision and shortening the computing time.
Further, in step 30, the types of the fusion-cast explosive material are specifically: the fused cast mixed explosive takes trinitrotoluene, 2, 4-dinitroanisole or 3, 4-dinitrofurazan oxide furazan or 1, 3-trinitroazetidine as main carriers. Further types of fused cast explosives may also be included.
Further, in step 30, the partial calculation parameters are specifically: the parameter range of the filling proportion fraction of the hemispherical casting is 0.995-0.999, the flow calculation is stopped after the filling proportion fraction reaches, and the maximum solving step number is 4000-6000 steps after the filling proportion reaches. The mold filling ratio parameter is a control parameter for regulating the flow process of the hemispherical casting.
Further, in step 40, the result file may further extract a shrinkage porosity calculation result.
The technical scheme provided by the invention can be applied to process design and model test in various hemispherical fusion-cast explosive casting processes. The creativity is as follows: and (5) a casting process virtualization model test aspect. On one hand, the sphere diameter of the hemispherical fusion cast explosive is used as a key control parameter in the geometric modeling process, and a geometric model covering various size ranges can be dynamically created; on the other hand, from the idea of simulation design, the core process links such as casting and solidification of the fusion-cast explosive are summarized into a model problem of mutual correlation between flow and heat transfer, and the method is abstract simplification and generalization of the essential problem of the casting process. The technical scheme provided by the invention provides a novel process simulation method, and meanwhile, the method can be combined with a specific practical process, and has strong operability and high practicability.
The invention has the following advantages:
(1) The sphere diameter is used as a key control parameter in the geometric model, and the method can be flexibly adjusted by combining with actual working conditions, so that the method is wide in applicable size and more in covering models;
(2) The technical scheme provided by the invention is clear and concise, detailed in thought, high in transportability and good in repeatability;
(3) The invention puts forward requirements on the grid quality of the computational grid, is beneficial to improving the computational accuracy, reducing the computational error and shortening the computation time.
Detailed Description
The present invention will be further illustrated with reference to the following examples, but the present invention is not limited to the following examples.
Example 1
The invention is applied to the simulation design of the casting process of the hemispherical fusion-cast explosive based on the TNT.
The melting and casting explosive based on the trinitrotoluene comprises the following components in percentage by mass: 26 parts of trinitrotoluene, 53 parts of cyclonite, 15 parts of fine aluminum powder and 6 parts of microcrystalline wax.
Step 10, calculating a model of a casting process of the hemispherical fusion-cast explosive based on trinitrotoluene, wherein the model comprises a hemispherical casting, a hemispherical bottom die, a frame and a base; firstly, establishing a geometric model of the hemispherical casting by adopting ANSYS design nModelr software in a mode of specifying a ball diameter, wherein the ball diameter is 100mm, and the geometric model is stored as a geometric file with a suffix file name of the igs format; repeating the steps to complete the construction work of the geometric models of the hemispherical bottom die, the frame and the base in sequence.
Step 20, guiding the geometric models of the hemispherical casting, the hemispherical bottom die, the frame and the base built in the step 10 into a ProCAST software visual mesh grid division component, checking the Boolean relationship of the geometric graph relationship of the four components, trimming redundant and overlapped parts, assembling and integrating the components to form a structural model for simulation calculation, controlling the grid quality by a method of randomly generating seeds, carrying out grid division on the structural model by adopting unstructured tetrahedral grids to form uniform and smooth calculation grids, wherein the grid length-width ratio range of the calculation grids is 1.0-5.0, the maximum value of the torsion degree is 20, and the Jacobian minimum value is 0.80.
Step 30, starting the VisualCast pretreatment assembly on the basis of the step 20, selecting a gravity casting mode as a casting mode, setting the hemispherical casting to be of a TNT-based fusion casting explosive material type, and setting the initial conditions to be 1.5m/s and 82 ℃ at the casting temperature; the hemispherical bottom die, the frame and the base are made of copper alloy metal materials, and the initial conditions comprise that the initial temperature is 20 ℃ and the filling proportion fraction is 1.0; the interface mode between the hemispherical casting and the hemispherical bottom die is selected as a consistency non-common node type, the boundary condition type is an interface heat exchange type, and the heat exchange coefficient is 500 W.m -2 ·K -1 Modifying part of calculation parameters by taking predefined gravity casting mode operation parameters as a reference, wherein the concrete steps are as follows: the filling proportion score parameter is 0.999, the flow calculation is stopped after the filling proportion score is reached, the maximum solving step number is 4000 steps after the filling proportion is reached, a user-defined calculation parameter file is formed, and a data file and a calculation parameter file are saved at the same time.
And step 40, taking the data file and the calculation parameter file saved in the step 30 as the basis, calling a flow analysis and thermal analysis solver to calculate the casting process of the hemispherical cast explosive, accelerating the calculation process by applying a multi-core technology, automatically outputting a result file after the calculation is finished, and extracting the results of a flow field and a temperature field by adopting a VisualViewer visual component to finish the simulation of the casting process of the hemispherical cast explosive based on the TNT.
In the embodiment, the operation process is detailed, the sphere diameter is used as a key control parameter, the geometric model can be flexibly created, and meanwhile, the grid quality of the computational grid is high, so that the computational error is reduced, and the computation time is shortened.
Example 2
The invention is applied to the simulation design of the casting process of the hemispherical casting explosive based on 2, 4-dinitroanisole.
The mass fraction of the components of the fused cast explosive based on 2, 4-dinitroanisole is as follows: 29 parts of 2, 4-dinitroanisole, 25 parts of hexogen, 20 parts of ammonium perchlorate, 20 parts of fine aluminum powder, 4 parts of insensitive wax and 2 parts of N-methyl paranitroaniline.
Step 10, calculating a model of the casting process of the hemispherical casting explosive based on 2, 4-dinitroanisole, wherein the model comprises a hemispherical casting, a hemispherical bottom die, a frame and a base; firstly, adopting ANSYS design nModelr software to construct a geometric model of the hemispherical casting in a mode of specifying the ball diameter, wherein the ball diameter is 40mm, and storing the geometric model as a geometric file with a suffix file name of an igs format; repeating the steps to complete the construction work of the geometric models of the hemispherical bottom die, the frame and the base in sequence.
Step 20, guiding the geometric models of the four components, namely the hemispherical casting, the hemispherical bottom die, the frame and the base, constructed in the step 10 into a ProCAST software visual mesh meshing component, checking the Boolean relationship of the geometric graph relationship of the four components, trimming redundant and overlapped parts, assembling and integrating the components to form a structural model for simulation calculation, controlling the mesh quality by a method of randomly generating seeds, meshing the structural model by adopting unstructured tetrahedral meshes to form uniform and smooth computational meshes, wherein the mesh length-width ratio range of the computational meshes is 1.0-6.0, the maximum value of the torsion degree is 25, and the Jacobian minimum value is 0.75.
Step 30, starting the VisualCast pretreatment assembly on the basis of the step 20, selecting a gravity casting mode as a casting mode, setting a hemispherical casting to be a 2, 4-dinitroanisole-based casting explosive material type, and setting the initial conditions to be 1.0m/s of casting speed and 94 ℃ of casting temperature; the hemispherical bottom die, the frame and the base are made of copper alloy metal materials, and the initial conditions comprise an initial temperature of 40 ℃ and a mold filling proportion fraction of 1.0; the interface mode between the hemispherical casting and the hemispherical bottom die is selected as a consistency non-common node type, the boundary condition type is an interface heat exchange type, and the heat exchange coefficient is 800 W.m -2 ·K -1 Modifying part of calculation parameters by taking predefined gravity casting mode operation parameters as a reference, wherein the concrete steps are as follows: the filling proportion score parameter is 0.997, the flow calculation is stopped after the filling proportion score is reached, the maximum solving step number is 4500 steps after the filling proportion is reached, a user-defined calculation parameter file is formed, and a data file and a calculation parameter file are stored at the same time.
And step 40, taking the data file and the calculation parameter file saved in the step 30 as the basis, calling a flow analysis and thermal analysis solver to calculate the casting process of the hemispherical fusion-cast explosive, accelerating the calculation process by using a multi-core technology, automatically outputting a result file after the calculation is finished, and extracting the results of a flow field and a temperature field by using a VisualViewer visual component to finish the simulation of the casting process of the hemispherical fusion-cast explosive based on the 2, 4-dinitroanisole.
In the embodiment, the operation process is detailed, the sphere diameter is used as a key control parameter, a geometric model can be flexibly created, and meanwhile, the grid quality of the computational grid is high, so that the computational error is reduced, and the computation time is shortened.
Example 3
The invention is applied to the simulation design of the casting process of the hemispherical fusion-cast explosive based on 3, 4-dinitrofurazan-based furoxan.
The fused and cast explosive based on 3, 4-dinitrofurazan oxide furazan comprises the following components in percentage by mass: 3, 4-dinitrofurazan oxide furazan 30 parts, octogen 49 parts, fine aluminum powder 14 parts, insensitive wax 6 parts and benzotrifuroxan 1 part.
Step 10, calculating a model in the casting process of the hemispherical fusion-cast explosive based on 3, 4-dinitrofurazan base-furoxan, wherein the model comprises a hemispherical casting, a hemispherical bottom die, a frame and a base; firstly, adopting ANSYS design nModelr software to construct a geometric model of a hemispherical casting in a mode of specifying a ball diameter, wherein the ball diameter is 30mm, and storing the geometric model as a geometric file with a suffix file name of an igs format; repeating the steps to complete the construction work of the geometrical models of the hemispherical bottom die, the frame and the base in sequence.
Step 20, guiding the geometric models of the four components, namely the hemispherical casting, the hemispherical bottom die, the frame and the base, constructed in the step 10 into a ProCAST software visual mesh grid division component, checking the Boolean relationship of the geometric graph relationship of the four components, trimming redundant and overlapped parts, assembling and integrating the components to form a structural model for simulation calculation, controlling the grid quality by a method of randomly generating seeds, carrying out grid division on the structural model by adopting unstructured tetrahedral grids to form uniform and smooth calculation grids, wherein the grid length-width ratio range of the calculation grids is 1.0-7.0, the maximum value of the torsion degree is 30, and the Jacobian minimum value is 0.70.
Step 30, starting the VisualCast pretreatment assembly on the basis of the step 20, selecting a gravity casting mode as a casting mode, setting a hemispherical casting to be a 3, 4-dinitrofurazan-based furoxan-based fusion casting explosive material type, and setting the initial conditions to be 0.2m/s of casting speed and 123 ℃ of casting temperature; the hemispherical bottom die, the frame and the base are made of copper alloy metal materials, and the initial conditions comprise an initial temperature of 60 ℃ and a mold filling proportion fraction of 1.0; selectingThe interface mode between the fixed hemispherical casting and the hemispherical bottom die is a consistent non-shared node type, the boundary condition type is an interface heat exchange type, and the heat exchange coefficient is 1000 W.m -2 ·K -1 Modifying part of calculation parameters by taking predefined gravity casting mode operation parameters as a reference, wherein the concrete steps are as follows: and the filling proportion score parameter is 0.995, the flow calculation is stopped after the filling proportion score is reached, the maximum solving step number is 6000 steps after the filling proportion is reached, a user-defined calculation parameter file is formed, and the data file and the calculation parameter file are stored at the same time.
And step 40, taking the data file and the calculation parameter file saved in the step 30 as the basis, calling a flow analysis and thermal analysis solver to calculate the casting process of the hemispherical fusion-cast explosive, accelerating the calculation process by applying a multi-core technology, automatically outputting a result file after the calculation is finished, extracting the results of a flow field and a temperature field by adopting a VisualViewer visual component, and finishing the simulation of the casting process of the hemispherical fusion-cast explosive based on the 3, 4-dinitrofurazan-based furoxan.
In the embodiment, the operation process is detailed, the sphere diameter is used as a key control parameter, a geometric model can be flexibly created, and meanwhile, the grid quality of the computational grid is high, so that the computational error is reduced, and the computation time is shortened.
Example 4
The invention is applied to the simulation design of the casting process of the hemispherical fusion-cast explosive based on 1, 3-trinitroazetidine.
The fused cast explosive based on 1, 3-trinitroazetidine comprises the following components in percentage by mass: 22 parts of 1, 3-trinitroazetidine, 5 parts of trinitro-trinitro, 3, 4-dinitrofurazan oxide furazan, 46 parts of hexogen, 19 parts of fine aluminum powder, 3 parts of insensitive wax and 2 parts of plasticizer.
Step 10, taking 1, 3-trinitroazetidine as a base to calculate a model in the casting process of the hemispherical fusion-cast explosive, wherein the model comprises a hemispherical casting, a hemispherical bottom die, a frame and a base; firstly, establishing a geometric model of the hemispherical casting by adopting ANSYS design nModelr software in a mode of specifying the ball diameter, wherein the ball diameter is 20mm, and the geometric model is stored as a geometric file with a suffix file name of the igs format; repeating the steps to complete the construction work of the geometric models of the hemispherical bottom die, the frame and the base in sequence.
And 20, importing the geometric models of the four components of the hemispherical casting, the hemispherical bottom die, the frame and the base, which are constructed in the step 10, into a ProCAST software Visualmesh partitioning component, checking the Boolean relationship of the geometric graph relationship of the four components, trimming redundant and overlapped parts, assembling and integrating the components to form a structural model for simulation calculation, controlling the grid quality by a method of randomly generating seeds, and performing mesh partitioning on the structural model by adopting an unstructured tetrahedral mesh to form a uniform and smooth computational mesh, wherein the mesh aspect ratio range of the computational mesh is 1.0-5.5, the maximum torsion degree is 25, and the Jacobian minimum value is 0.75.
Step 30, starting the VisualCast pretreatment assembly on the basis of the step 20, selecting a gravity casting mode as a casting mode, setting a hemispherical casting to be a 1, 3-trinitroazetidine-based fusion casting explosive material type, and setting the initial conditions to be 0.8m/s of casting speed and 101 ℃ of casting temperature; the hemispherical bottom die, the frame and the base are made of copper alloy metal materials, and the initial conditions comprise an initial temperature of 50 ℃ and a mold filling proportion fraction of 1.0; the interface mode between the hemispherical casting and the hemispherical bottom die is selected as a consistency non-common node type, the boundary condition type is an interface heat exchange type, and the heat exchange coefficient is 900 W.m -2 ·K -1 Modifying part of calculation parameters by taking predefined gravity casting mode operation parameters as a reference, wherein the concrete steps are as follows: the filling proportion score parameter is 0.996, the flow calculation is stopped after the filling proportion score is reached, the maximum solving step number is 6000 steps after the filling proportion is reached, a user-defined calculation parameter file is formed, and the data file and the calculation parameter file are stored at the same time.
And step 40, taking the data file and the calculation parameter file saved in the step 30 as the basis, calling a flow analysis and thermal analysis solver to calculate the casting process of the hemispherical fusion-cast explosive, accelerating the calculation process by using a multi-core technology, automatically outputting a result file after the calculation is finished, extracting the results of the flow field and the temperature field by using a VisualViewer visual component, and finishing the simulation of the casting process of the hemispherical fusion-cast explosive based on 1, 3-trinitroazetidine.
In the embodiment, the operation process is detailed, the sphere diameter is used as a key control parameter, a geometric model can be flexibly created, and meanwhile, the grid quality of the computational grid is high, so that the computational error is reduced, and the computation time is shortened.
Although the invention has been described herein with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure.
Claims (5)
1. A simulation method for a casting process of a hemispherical fusion cast explosive is characterized by comprising the following steps:
step 10, calculating a model in the casting process of the hemispherical fusion-cast explosive, wherein the model comprises a hemispherical casting, a hemispherical bottom die, a frame and a base; firstly, adopting ANSYS design nModelr software to construct a geometric model of a hemispherical casting in a mode of designating a sphere diameter, storing the geometric model as a geometric file with a suffix file name of an igs format, then continuously using GeoMesh software to reopen the geometric file with the saved igs format, trimming a geometric figure, and storing the geometric file as a geometric file with a suffix file name of an iges format, so as to complete the construction work of the geometric model of the hemispherical casting; repeating the steps to complete the construction work of the geometric models of the hemispherical bottom die, the frame and the base in sequence;
step 20, importing the geometric models of the four components of the hemispherical casting, the hemispherical bottom die, the frame and the base, which are constructed in the step 10, into a ProCAST software visual mesh meshing component, checking the Boolean relationship of the geometric graph relationship of the four components, trimming redundant and overlapped parts, assembling and integrating the components to form a structural model for simulation calculation, controlling the mesh quality by a method of randomly generating seeds, and meshing the structural model by adopting unstructured tetrahedral meshes to form uniform and smooth calculation meshes;
step 30, starting the VisualCast pretreatment component on the basis of the step 20, selecting a gravity casting mode as a casting mode, setting the hemispherical casting as a fusion-cast explosive material type, setting the initial conditions to be a metal material type, setting the initial conditions to be a casting speed of 0.2-1.5 m/s and a casting temperature of 82-123 ℃, setting the hemispherical bottom die, the frame and the base as metal material types, setting the initial conditions to be a filling proportion fraction of 1.0, selecting an interface mode between the hemispherical casting and the hemispherical bottom die as a consistency non-common node type, setting the boundary condition type as an interface heat exchange type, and setting the heat exchange coefficient to be 500 W.m -2 ·K -1 ～1000W·m -2 ·K -1 Modifying part of calculation parameters in a predefined gravity casting mode by taking the operation parameters as a reference to form a user-defined calculation parameter file, and simultaneously storing a data file and a calculation parameter file;
and step 40, taking the data file and the calculation parameter file saved in the step 30 as the basis, calling a flow analysis and thermal analysis solver to calculate the casting process of the hemispherical cast explosive, accelerating the calculation process by using a multi-core technology, automatically outputting a result file after the calculation is finished, and extracting the results of a flow field and a temperature field by using a VisualViewer visual component to finish the simulation of the casting process of the hemispherical cast explosive.
2. The method for simulating a casting process of a hemispherical fusion cast explosive according to claim 1, wherein in the step 10, the sphere diameter is in the range of 20mm to 100mm.
3. The method for simulating the casting process of the hemispherical fusion-cast explosive according to claim 1, wherein in the step 20, the grid quality specifically comprises: the maximum value of the grid torsion degree is not more than 30, and the Jacobian minimum value is not less than 0.7.
4. The method for simulating a casting process of a hemispherical fusion-cast explosive according to claim 1, wherein in step 30, the types of the fusion-cast explosive materials are specifically: the fusion-cast mixed explosive takes trinitrobenzene, 2, 4-dinitroanisole, 3, 4-dinitrofurazan oxide furazan or 1, 3-trinitroazetidine as main carriers.
5. The method for simulating the casting process of the hemispherical fusion-cast explosive according to claim 1, wherein in the step 30, the partial calculation parameters are specifically: the parameter range of the filling proportion fraction of the hemispherical casting is 0.995-0.999, the flow calculation is stopped after the filling proportion fraction reaches, and the maximum solving step number is 4000-6000 steps after the filling proportion reaches.
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