CN114101584B - Simulation casting research method based on generator impeller plate - Google Patents
Simulation casting research method based on generator impeller plate Download PDFInfo
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- CN114101584B CN114101584B CN202111384388.6A CN202111384388A CN114101584B CN 114101584 B CN114101584 B CN 114101584B CN 202111384388 A CN202111384388 A CN 202111384388A CN 114101584 B CN114101584 B CN 114101584B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/02—Sand moulds or like moulds for shaped castings
- B22C9/04—Use of lost patterns
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/08—Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
- B22C9/082—Sprues, pouring cups
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
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- G06F30/20—Design optimisation, verification or simulation
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Abstract
The invention belongs to the technical field of high-temperature alloy investment precision casting application, and particularly discloses a simulation casting research method based on a generator impeller plate, which comprises the following steps, and (1) carrying out the evaluation of the generator impeller plate wax pattern model through alloy casting simulation software, and inputting the data parameters of the generator impeller plate wax pattern model and the simulation environment setting by combining the evaluation parameters and the analysis results of the generator impeller plate wax pattern model. And (2) inputting simulation calculation parameters, performing simulation calculation by using alloy casting simulation software, observing the calculation result of the alloy casting simulation software, and analyzing. The invention has the beneficial effects that: by simulating the alloy cast generator impeller plates under different mould shell conditions and combining the simulation and analysis, the mould shell parameters, temperature parameters and the like of the generator impeller plates cast by utilizing the high-temperature alloy investment technology are obtained, the quality and the working efficiency of the cast generator impeller plates are improved, and the processing cost is reduced.
Description
Technical Field
The invention belongs to the technical field of high-temperature alloy investment precision casting application, and particularly relates to a simulation casting research method based on a generator impeller plate, in particular to the manufacturing process problem of the generator impeller plate.
Background
Investment precision casting and directional solidification of superalloys are one of the key technologies for manufacturing single crystal (or directional crystallization) turbine blades for aeroengines and gas turbines.
Along with the development of the high-temperature alloy investment technology, people also consider that the high-temperature alloy investment technology is used for casting the generator impeller disc, so that the casting process of the high-temperature alloy investment technology needs to be simulated and calculated, the quality and the working efficiency of the cast generator impeller disc are improved, and the processing cost is reduced.
Based on the problems, the invention provides a simulation casting research method based on a generator impeller plate.
Disclosure of Invention
The invention aims to: the invention aims to provide a simulation casting research method based on a generator impeller plate, which solves the problems existing in casting alloy generator impeller plates by using a high-temperature alloy investment technology.
The technical scheme is as follows: the invention provides a simulation and simulation casting research method based on a generator impeller plate, which comprises the following steps that step (1) carries out the evaluation of a generator impeller plate wax pattern model through alloy casting simulation software, and combines the evaluation parameters and analysis results of the generator impeller plate wax pattern model, and inputs the data parameters of the generator impeller plate wax pattern model and the simulation environment setting. And (2) inputting simulation calculation parameters, performing simulation calculation by using alloy casting simulation software, observing the calculation result of the alloy casting simulation software, and analyzing.
According to the technical scheme, in the step 1, a generator impeller plate wax pattern model is observed, measures are improved, and the generator impeller plate wax pattern model comprises the following conditions that (a) the thickness of the exhaust edge of a blade is smaller than 0.5mm, the phenomenon of underinjection exists, the wax pattern is thickened by 0.5mm, and the post-treatment is removed by rotary file polishing; (b) The thickness of the air inlet edge of the blade is smaller than 0.5mm, the phenomenon of underinjection exists, the wax mould is required to be thickened by 0.3mm, the post-treatment is removed by rotary file polishing, and meanwhile, the step on the outer side of the inner ring is filled; (c) the overall thickness of the blade exhaust edge is less than 1mm; (d) the inner ring flange has a thickness of 1.5mm; (e) The wall thickness of the outer ring of the part is 2mm, the step filling of the inner wall of the outer ring is used as a machining allowance to thicken to 3mm, so that feeding is improved; (f) exhaust side outer ring wall thickness 2.5mm; (g) Obtaining the shape and improvement of a generator impeller plate wax pattern, wherein the flange edge is filled into a circumferential shape, holes and grooves, and the characteristics of the holes and grooves need to be blocked; the simulation environment in the step 1 is set, firstly, the fillet parameter of the blade and the outer annular wall is set to be 1mm, then, the fillet parameter of the connecting surface of the inner annular flange and the inner wall ring is set to be 3mm, the hole fillet parameter of the inner annular flange is set to be 2.5mm, and finally, the fillet of the inner annular flange is increased.
According to the technical scheme, simulation calculation parameters in the step 2 are as follows: alloy brand, inconel 719; casting temperature, melting point +100 ℃; the preheating temperature of the mould shell is 1000 ℃; casting speed, 10 kg/s; pouring weight, 6.5kg; mould shell, mullite sand; the thickness of the mould shell is 5 layers/4 mm of the blade part and 8 layers/6 mm of the other parts; alloy melting point range, 1210-1344 ℃; alloy density, 8.2 g/cc.
In the technical scheme, two heat treatment systems exist in the simulation calculation parameters in the step 2: 1) High-temperature stretching and lasting are taken into consideration, heat preservation is carried out for 1 h+air cooling at 954-982 ℃ and 718 ℃/8 h+air cooling is carried out to 621 ℃ and 8 h+air cooling is carried out to room temperature; 2) And the temperature and the low-temperature stretching are taken into consideration, the temperature is kept at 1066 ℃ for 1-2 hours, the air cooling is carried out at-718 ℃/8 hours, the air cooling is carried out at 621 ℃, and the air cooling is carried out at 8 hours, so that the temperature is kept at room temperature.
According to the technical scheme, the pouring parameter input setting and result analysis in the step 2 comprise the following conditions that (a) the blade is not thickened, the blade starts to solidify firstly, and the blade solidifies always earlier than the inner ring and the outer ring; (b) The blades are not thickened, the inner ring and the outer ring are thickened by 1mm, the blades and the inner ring and the outer ring start to solidify almost simultaneously, and the blades and the inner ring solidify almost synchronously; (c) The blade is thickened by 1mm, the mold filling is basically finished by the pouring gate of the inner ring, the mold filling is finished in the area aligned with the pouring gate of the inner ring, the mold filling is finished in the other area, the solidification of the blade and the inner ring is almost simultaneously started, the solidification is almost synchronous in the follow-up, the solidification of the position of the riser of the outer ring is started at first, because the mold filling is finished at last, the heating time of alloy liquid is shortest, the solidification of the position of the riser of the inner ring is finished at last, the inner ring and the outer ring are solidified before the blade, the feeding of the blade is difficult, the solidification is finished at the transition arc, and the loosening and the crack are concentrated in the area.
According to the technical scheme, pouring parameters in the step 2 are input and set, and result analysis is carried out, wherein when pouring alloy is simulated in the steps (a) and (b), heat preservation cotton is arranged on the outer layer of the generator impeller plate wax mould model; (c) When the casting alloy is simulated, heat preservation cotton with the thickness of 20mm is arranged on the outer layer of the generator impeller plate wax mould model.
Compared with the prior art, the simulation casting research method based on the generator impeller plate has the beneficial effects that: by simulating the alloy cast generator impeller plates under different mould shell conditions and combining the simulation and analysis, the mould shell parameters, temperature parameters and the like of the generator impeller plates cast by utilizing the high-temperature alloy investment technology are obtained, the quality and the working efficiency of the cast generator impeller plates are improved, and the processing cost is reduced.
Drawings
FIG. 1 is a schematic diagram of step 1 scenario (a) of the present invention;
FIGS. 2 and 3 are schematic diagrams of the present invention in case (b) of step 1;
FIG. 4 is a schematic diagram of step 1 scenario (c) of the present invention;
FIG. 5 is a schematic diagram of step 1 scenario (d) of the present invention;
FIGS. 6 and 7 are schematic diagrams of the present invention in case (e) of step 1;
FIG. 8 is a schematic diagram of case (f) of step 1 of the present invention;
FIG. 9 is a schematic diagram of the simulated environment setup in step 1 of the present invention;
FIG. 10 is a schematic diagram of case (g) of step1 of the present invention;
FIG. 11 is a schematic diagram of step 2 scenario (a) of the present invention;
FIG. 12 is a schematic diagram of step 2 scenario (b) of the present invention;
fig. 13 and 14 are schematic diagrams of the step 2 scenario (c) of the present invention.
Detailed Description
The invention is further elucidated below in connection with the drawings and the specific embodiments.
The simulation casting research method based on the generator impeller plate shown in fig. 1 to 14 comprises the following steps that step (1) carries out the evaluation of a generator impeller plate wax pattern model through alloy casting simulation software, and combines the evaluation parameters and analysis results of the generator impeller plate wax pattern model, and inputs the data parameters and the simulation environment setting of the generator impeller plate wax pattern model. And (2) inputting simulation calculation parameters, performing simulation calculation by using alloy casting simulation software, observing the calculation result of the alloy casting simulation software, and analyzing.
The invention is based on the simulation and simulation casting research method of the generator impeller, in the step 1, by observing the generator impeller wax pattern model and carrying out measure improvement on the generator impeller wax pattern model, comprising the following situations,
(A) The thickness of the exhaust edge of the blade is less than 0.5mm, the underinjection phenomenon exists, the wax mould is required to be thickened by 0.5mm, and the post-treatment is removed by rotary file polishing;
(b) The thickness of the air inlet edge of the blade is smaller than 0.5mm, the phenomenon of underinjection exists, the wax mould is required to be thickened by 0.3mm, the post-treatment is removed by rotary file polishing, and meanwhile, the step on the outer side of the inner ring is filled;
(c) The overall thickness of the exhaust edge of the blade is less than 1mm;
(d) The thickness of the inner ring flange is 1.5mm;
(e) The wall thickness of the outer ring of the part is 2mm, the step filling of the inner wall of the outer ring is used as a machining allowance to thicken to 3mm, so that feeding is improved;
(f) The wall thickness of the outer ring at the exhaust side is 2.5mm;
(g) Obtaining the shape and improvement of a generator impeller plate wax pattern, wherein the flange edge is filled into a circumferential shape, holes and grooves, and the characteristics of the holes and grooves need to be blocked;
The simulation environment in the step 1 is set, firstly, the fillet parameter of the blade and the outer annular wall is set to be 1mm, then, the fillet parameter of the connecting surface of the inner annular flange and the inner wall ring is set to be 3mm, the hole fillet parameter of the inner annular flange is set to be 2.5mm, and finally, the fillet of the inner annular flange is increased.
The invention relates to a simulation casting research method based on a generator impeller, wherein simulation calculation parameters in step 2 are as follows: alloy brand, inconel 719; the melting point range of the alloy is 1210-1344 ℃; density of the alloy, 8.2 g/cc; the casting temperature, melting point +100deg.C (above melting point 100 ℃); the preheating temperature of the mould shell is 1000 ℃; casting speed, 10 kg/s; the casting weight is 6.5kg; the shuttering material, mullite sand; the thickness of the mould shell is 5 layers/4 mm (the thickness of 5 layers is 4 mm) of the blade part, and the thickness of the other part is 8 layers/6 mm (the thickness of 8 layers is 4 mm).
The invention relates to a simulation casting research method based on a generator impeller, wherein two heat treatment systems exist in simulation calculation parameters in the step 2: 1) High-temperature stretching and lasting are taken into consideration, heat preservation is carried out for 1 h+air cooling at 954-982 ℃ and 718 ℃/8 h+air cooling is carried out to 621 ℃ and 8 h+air cooling is carried out to room temperature; 2) And the temperature and the low-temperature stretching are taken into consideration, the temperature is kept at 1066 ℃ for 1-2 hours, the air cooling is carried out at-718 ℃/8 hours, the air cooling is carried out at 621 ℃, and the air cooling is carried out at 8 hours, so that the temperature is kept at room temperature.
The invention relates to a simulation casting research method based on a generator impeller plate, wherein pouring parameter input setting and result analysis in the step 2 comprise the following situations,
(A) The blades are not thickened, the blades start to solidify firstly, and the solidification of the blades is always earlier than that of the inner ring and the outer ring;
(b) The blades are not thickened, the inner ring and the outer ring are thickened by 1mm, the blades and the inner ring and the outer ring start to solidify almost simultaneously, and the blades and the inner ring solidify almost synchronously;
(c) The blade is thickened by 1mm, the mold filling is basically finished by the pouring gate of the inner ring, the mold filling is finished in the area aligned with the pouring gate of the inner ring, the mold filling is finished in the other area, the solidification of the blade and the inner ring is almost simultaneously started, the solidification is almost synchronous in the follow-up, the solidification of the position of the riser of the outer ring is started at first, because the mold filling is finished at last, the heating time of alloy liquid is shortest, the solidification of the position of the riser of the inner ring is finished at last, the inner ring and the outer ring are solidified before the blade, the feeding of the blade is difficult, the solidification is finished at the transition arc, and the loosening and the crack are concentrated in the area.
According to the method, based on the simulation casting research method of the generator impeller, pouring parameters are input and set and result analysis are carried out in the step 2, and when pouring alloy is simulated in the steps (a) and (b), heat-insulating cotton is arranged on the outer layer of a wax mould model of the generator impeller; (c) When the casting alloy is simulated, heat preservation cotton with the thickness of 20mm is arranged on the outer layer of the generator impeller plate wax mould model.
The invention relates to a simulation casting research method based on a generator impeller plate, and alloy casting simulation software is ProCAST.
The foregoing is merely a preferred embodiment of the invention, and it should be noted that modifications could be made by those skilled in the art without departing from the principles of the invention, which modifications would also be considered to be within the scope of the invention.
Claims (3)
1. The simulation casting research method based on the generator impeller disc is characterized by comprising the following steps of: comprises the steps of,
Step (1) carrying out the evaluation of the generator impeller wax pattern model through alloy casting simulation software, and inputting the data parameters of the generator impeller wax pattern model and the simulation environment setting by combining the evaluation parameters and the analysis results of the generator impeller wax pattern model;
Step (2) inputting simulation calculation parameters, performing simulation calculation by using alloy casting simulation software, observing calculation results of the alloy casting simulation software and analyzing;
In the step 1, by observing the generator impeller plate wax model and performing measure improvement on the generator impeller plate wax model, including the following situations,
(A) The thickness of the exhaust edge of the blade is less than 0.5mm, the underinjection phenomenon exists, the wax mould is required to be thickened by 0.5mm, and the post-treatment is removed by rotary file polishing;
(b) The thickness of the air inlet edge of the blade is smaller than 0.5mm, the phenomenon of underinjection exists, the wax mould is required to be thickened by 0.3mm, the post-treatment is removed by rotary file polishing, and meanwhile, the step on the outer side of the inner ring is filled;
(c) The overall thickness of the exhaust edge of the blade is less than 1mm;
(d) The thickness of the inner ring flange is 1.5mm;
(e) The wall thickness of the outer ring of the part is 2mm, the step filling of the inner wall of the outer ring is used as a machining allowance to thicken to 3mm, so that feeding is improved;
(f) The wall thickness of the outer ring at the exhaust side is 2.5mm;
(h) Obtaining the shape and improvement of a generator impeller plate wax pattern, wherein the flange edge is filled into a circumferential shape, holes and grooves, and the characteristics of the holes and grooves need to be blocked;
setting the simulation environment in the step 1, firstly setting the fillet parameters of the blades and the outer annular wall to be 1mm, setting the fillet parameters of the connecting surface of the inner annular flange and the inner wall ring to be 3mm, setting the hole fillet parameters of the inner annular flange to be 2.5mm, and finally increasing the fillet of the inner annular flange;
The simulation calculation parameters in the step 2 are as follows: alloy brand, inconel 719; casting temperature, melting point +100 ℃; the preheating temperature of the mould shell is 1000 ℃; casting speed, 10 kg/s; pouring weight, 6.5kg; mould shell, mullite sand; the thickness of the mould shell is 5 layers/4 mm of the blade part and 8 layers/6 mm of the other parts; alloy melting point range, 1210-1344 ℃; alloy density, 8.2 g/cc;
In the simulation calculation parameters of the step 2, there are two heat treatment systems: 1) High-temperature stretching and lasting are taken into consideration, heat preservation is carried out for 1 h+air cooling at 954-982 ℃ and 718 ℃/8 h+air cooling is carried out to 621 ℃ and 8 h+air cooling is carried out to room temperature; 2) And the temperature and the low-temperature stretching are taken into consideration, the temperature is kept at 1066 ℃ for 1-2 hours, the air cooling is carried out at-718 ℃/8 hours, the air cooling is carried out at 621 ℃, and the air cooling is carried out at 8 hours, so that the temperature is kept at room temperature.
2. The simulated casting study method based on the generator impeller plate of claim 1, wherein the method comprises the following steps: the casting parameter input setting and result analysis of step 2 includes the following cases,
(A) The blades are not thickened, the blades start to solidify firstly, and the solidification of the blades is always earlier than that of the inner ring and the outer ring;
(b) The blades are not thickened, the inner ring and the outer ring are thickened by 1mm, the blades and the inner ring and the outer ring start to solidify almost simultaneously, and the blades and the inner ring solidify almost synchronously;
(c) The blade is thickened by 1mm, the mold filling is basically finished by the pouring gate of the inner ring, the mold filling is finished in the area aligned with the pouring gate of the inner ring, the mold filling is finished in the other area, the solidification of the blade and the inner ring is almost simultaneously started, the solidification is almost synchronous in the follow-up, the solidification of the position of the riser of the outer ring is started at first, because the mold filling is finished at last, the heating time of alloy liquid is shortest, the solidification of the position of the riser of the inner ring is finished at last, the inner ring and the outer ring are solidified before the blade, the feeding of the blade is difficult, the solidification is finished at the transition arc, and the loosening and the crack are concentrated in the area.
3. The simulated casting study method based on the generator impeller plate of claim 2, wherein the method comprises the following steps: the pouring parameters of the step 2 are input and set and analyzed,
(A) And (b) when the casting alloy is simulated, arranging heat-insulating cotton on the outer layer of the generator impeller wax pattern model;
(c) When the casting alloy is simulated, heat preservation cotton with the thickness of 20mm is arranged on the outer layer of the generator impeller plate wax mould model.
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| FR3146608A1 (en) * | 2023-03-17 | 2024-09-20 | Safran | PROCESS FOR MANUFACTURING A MOLD FOR CASTING A METAL PART MADE BY LOST WAX CASTING |
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| CN102441642A (en) * | 2011-12-06 | 2012-05-09 | 中国航空工业集团公司北京航空材料研究院 | Method for preventing blades of whole turbine impeller of high temperature alloy from under-casting |
| CN105302985A (en) * | 2015-11-12 | 2016-02-03 | 哈尔滨工业大学 | Alloy micro-cast forming process simulation method based on fluent software |
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| CN112001037B (en) * | 2020-06-11 | 2024-06-04 | 北京科技大学 | Simulation method for casting forming of dual-performance blisk |
| CN112100819B (en) * | 2020-08-24 | 2024-02-13 | 上海交通大学 | A casting riser design method based on integrated computing and data-driven |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN102441642A (en) * | 2011-12-06 | 2012-05-09 | 中国航空工业集团公司北京航空材料研究院 | Method for preventing blades of whole turbine impeller of high temperature alloy from under-casting |
| CN105302985A (en) * | 2015-11-12 | 2016-02-03 | 哈尔滨工业大学 | Alloy micro-cast forming process simulation method based on fluent software |
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