現代鑄造

土木工程論文編號:TM010  論文字數:14321,頁數:44

目錄
摘要 I
ABSTRACT II

第1章 緒論 1
1.1 現代鑄造的狀況及發展趨勢 1
1.1.1 鑄造生產的特點 1
1.1.2國內外鑄造技術的現狀、存在問題及發展趨勢 2
1.2計算機技術在鑄造的應用 3
1.2.1計算機數值模擬的優點 4
1.2.2計算機輔助設計及鑄造過程計算機模擬與傳統鑄造技術的比較 5
1.3課題的提出及研究內容 5
1.3.1課題的提出 5
1.3.2課題任務及研究內容 6
第2章 礦井天輪鑄造工藝設計 7
2.1零件的鑄造工藝性分析 7
2.1.1零件結構材質和技術要求 8
2.1.2鑄件質量對零件結構的要求 8
2.1.3鑄造工藝對零件的結構要求 8
2.2造型方法的選擇 10
2.3工藝方案的確定 10
2.3.1澆注位置的確定 10
2.3.2分型面的確定 11
2.3.3鑄件澆注溫度的確定 11
2.4工藝參數的確定 11
2.4.1鑄件尺寸公差 11
2.4.2機械加工余量 12
2.4.3鑄件線收縮率 12
2.4.4起模斜度 12
2.4.5最小鑄出孔 12
2.5砂芯設計 13
2.6澆注系統設計 13
2.6.1澆注形式及注入位置的選擇 14
2.6.2鑄件模數 15
2.6.3直澆道的位置和高度 15
2.6.4澆注時間的確定 16
2.6.5澆注系統的截面積 16
2.6.6冒口與冷鐵設計 18
第3章 凝固過程數值模擬 21
3.1鑄件凝固過程數值模擬技術的原理 21
3.2 View Cast的實現過程 22
3.3模擬結果及其分析 23
3.3.1輪緣初始方案模擬結果及其分析 24
3.3.2輪緣優化方案模擬結果及其分析 26
3.3.3輪轂初始方案模擬結果及其分析 30
3.3.4輪轂優化方案模擬結果及其分析 33
結論 38
參考文獻 39
致謝 40 

摘要
 本文運用傳統方法完成了對礦井天輪的鑄造工藝方案設計，包括鑄造方法、澆注位置、分型面的選擇，各項鑄造工藝參數的確定，以及澆注系統、冒口、冷鐵的設計。根據天輪的結構特點及質量要求，對天輪輪轂、輪緣進行差時澆注。通過在天輪輪轂頂部設計兩個保溫冒口，在輪緣熱節處上方放置冒口以及在輪轂厚大部位加冷鐵，以期實現順序凝固。建立鑄件、澆注系統及冒口的三維實體模型，運用View Cast鑄造模擬軟件對天輪的凝固過程進行了計算。其結果顯示，輪緣熱節處、輪轂壁厚大部位最后凝固且產生縮孔縮松缺陷。根據模擬結果及分析，通過加大保溫冒口尺寸、冷鐵厚度，對鑄造工藝進行優化。再次模擬的結果表明，優化工藝能將缺陷轉移到冒口中，實現了順序凝固，從而最大程度地消除了鑄造缺陷，獲得了合理的鑄造工藝方案。

關鍵詞：天輪；工藝優化；凝固過程；數值模擬
ABSTRACT
In this paper, the design of the casting process was obtained by traditional casting design method. The process consist of the choice of the casting, parting and casting position, the determination of casting parameters and the design of the gating system, risers and cold iron. According to the structural characteristics of sheave and quality requirements, the sheave wheels and rim be poured separately. In order to achieve progressive solidification, two heat risers were laid on the top of the wheel, some heat risers were placed on the top of the hot spot in the rim and cold iron was introduced near by the thick part of the wheel hub. Three-dimensional model of the casting was built and the solidification process of the sheave was simulated by use of View Cast. The results showed that the hot spot areas in the rim and thick part of the wheel hub freeze finally, and the shrinkage generated in these areas. According to the simulation results and analysis, the casting process program was optimized by means of increasing the size of riser and thickness of the cold iron. After simulated once again, the defects were transformed to risers. The defects were eliminated to the greatest extent and the progressive solidification was achieved. So the reasonable program of the casting process was obtained.

 Key Words: Sheave; Process optimization; Casting process; Numerical simulation