Design Of Multidimensional Vibration Water Simulation Experiment Platform And Research On Filling Mechanism

In traditional casting,the high temperature,dynamic and instantaneous flow of molten metal and the opacity of sand mold make it impossible to directly observe the filling and flow of molten metal in the mold cavity.At the same time,the vibration mode and track of the excitation device on the water simulation test bench used at present are single,and the degree of freedom is few,so it is difficult to meet the molding requirements of medium and large castings with complex structure.In order to solve the problems of opaque filling flow of molten metal,single track of excitation device and few degrees of freedom in casting forming process,a multidimensional vibration water simulation experimental platform was designedBy expounding the similarity principle and the mechanism of water simulation technology,the feasibility of water simulation technology is analyzed theoretically.The analysis results show that when the prototype and the model are geometrically similar and the flow is in the self modeling region,as long as the Fr number is equal,the fluid in the prototype and the model will meet the thermodynamic similarity.Based on TRIZ theory,a multidimensional vibration water simulation experimental platform was designed based on mechanism topological structure principle,similarity principle and multidimensional vibration casting theory.The main structure of the experimental platform was analyzed statically,and the results met the design requirements.At the same time,a 3-DOF electromagnetic vibration experimental platform is selected as a multidimensional vibration experimental platform to optimize the casting filling process.Finally,the gating systems of three typical parts are designed,which are shaft sleeve parts,disk cover parts and box partsTaking automobile crankshafts as the research object,the filling and solidification processes of crankshaft castings with bottom pouring,middle pouring and top pouring schemes were studied by using ProCAST software.The simulation results show that the molding quality of middle pouring system is better,but the porosity of castings with middle pouring scheme exceeds the standard.Then,the designed gating system is optimized by adding external chills and adding inverted cone vent holes at defect positions.The simulation results show that the shrinkage cavity volume of the optimized casting decreases by 4.512382cc.Finally,the influence of pouring temperature and pouring time on the molding quality of castings is explored by using the optimization scheme.The simulation results show that when pouring temperature is 1400～1420℃ and pouring time is 8s,the forming quality of crankshaft is the best.Using discrete element software and control variable method,the filling flow of molten metal in casting cavity was simulated by the flow of fine particles,and the influence of different vibration parameters on the filling performance of castings was analyzed.The simulation results show that when the degree of freedom of vibration DOF=3,the vibration frequency f=50Hz and the vibration amplitude A=0.75mm,the filling flow performance of castings is the best.At the same time,the orthogonal test method is used to analyze the influence of different vibration parameters on the filling performance of crankshaft.The simulation results show that the vibration amplitude has the greatest influence on the filling distance of particles in the cavity.The filling distance of particles in the cavity is 505.55mm after simulation with the best process parameters.Compared with the mold filling distance without vibration scheme,the mold filling distance with vibration scheme is increased by 242.38mm,which further verifies the rationality of the optimum process parameters of simulation experiment.Finally,based on the similarity principle,a multidimensional vibration water simulation experimental platform is built,and the selection of components of the test-bed is introduced.Then,taking the crankshaft model as the experimental research object,the physical experiments of three pouring schemes of crankshaft castings were completed by using the multidimensional vibration water simulation experimental platform.The experimental results show that the results of similar simulation experiments are consistent with those of simulation experiments,which proves the accuracy of simulation experiments and the feasibility of the experimental platform.Figure[60]Table[27]Reference[120]...