摘 要

随着CAD/CAE软件的不断发展和商业化，由于其应用广泛且具实用性，为企业生产创收取得了可观的效益。因此，越来越多的企业将其应用到生产实践中，指导生产和工艺优化开发。

铸件凝固过程数值模拟是极为有效的铸造工艺CAE方法，通过ProCAST专业软件进行铸件凝固过程数值模拟分析，可以预测铸造缺陷产生的位置，继而分析其原因，方便改进工艺。通过进一步优化铸造工艺参数，保障铸件质量，提高出品率，从而提高企业效益和市场竞争力。

本文的工作是针对某公司的出口德国的熔模铸造小铸钢件的特殊结构易导致废品率高的问题，拟进行铸件凝固过程数值模拟分析，确定缩孔缺陷产生原因，优化工艺方案，在达到客户的质量需求前提下，提高成品率。

本文通过设计不同方案，利用Pro/E造型并划分网格，进而采用ProCAST进行凝固模拟分析。在原工艺模拟的基础上，优化工艺参数，保证铸件质量。对不同制备工艺进行工艺技术及经济效益分析，综合推出该铸件的优化方案，研究结果用于试生产铸件，得到合格铸件。

关键词：数值模拟；熔模铸造；ProCAST软件；缩孔缺陷；工艺优化

Abstract

With the development and commercialization of the CAD / CAE software，its wide application and practical for the production revenue which achieved substantial benefits. Therefore, more and more enterprises will apply it to the production practice to guide the development of production and process optimization.

Numerical simulation of solidification process is an extremely effective casting process research method to simulate the solidification process analysis through the ProCAST software. It can predict the position of casting defects, and then analyze the reasons. It is convenient to facilitate process improvements.

By further optimizing the casting process parameters to ensure casting quality, increase yield, to improve enterprise efficiency and market competitiveness.

The article is the work of the special structure of the high rejection rate for a company exports a small German investment casting steel castings and other issues. It is difficult to meet the demand of quality. Intend to simulate the solidification process analysis to make sure the cause of shrinkage defects, and then optimize technology programs to improve the production rate.

Making different scenarios, with Pro / E modeling and mesh, and then use ProCAST software to make solidification simulation. On the basis of the original process simulation, optimize the process parameters to ensure the quality of castings. Consider different processes for the preparation of technology and economic analysis, and then extract the optimization. The results have been used in trial production of castings and get qualified castings.

Keywords: Numerical simulation ；Process of investment casting; ProCAST software; Shrinkage defect process optimization

目 录

摘要................................................................................................................................................I

Abstract.........................................................................................................................................II

目录..............................................................................................................................................III

第1章 绪论..................................................................................................................................1

1.1 选题背景及意义.......................................................................................................1

1.2 熔模铸造的发展.......................................................................................................2

1.2.1 熔模铸造在国外的发展................................................................................2

1.2.2 熔模铸造在国内的发展................................................................................3

1.3 国内外凝固过程数值模拟发展...............................................................................3

1.3.1 国内外数值模拟软件概况............................................................................4

1.3.2 ProCAST软件的基本模块和特点.................................................................5

1.3.3 Pro/Engineer造型软件...............................................................................7

1.4课题研究内容............................................................................................................8

第2章 熔模铸钢件方案设计......................................................................................................9

2.1 熔模铸钢件结构特点及铸造工艺设计...................................................................9

2.1.1 浇注系统设计................................................................................................9

2.1.2 铸造工艺方案设计......................................................................................10

2.2 凝固过程参数条件的处理.....................................................................................10

2.2.1 初始条件......................................................................................................10

2.2.2 边界条件......................................................................................................10

2.2.3 几何条件......................................................................................................10

2.2.4 材料热物性参数..........................................................................................12

2.3 缩孔缩松缺陷的预测.............................................................................................12

第3章 铸件数值模拟和工艺优化............................................................................................14

3.1 铸件原工艺介绍.....................................................................................................14

3.2 铸件工艺模型改进设计和处理.............................................................................14

3.2.1 模型组装......................................................................................................15

3.2.2 Pro/E网格划分和图形数据转换...............................................................16