Numerical Simulation of Solidification and Shrinkage Prediction of Cast Irons

研究将开发基于数值模拟的收缩 铸件优化设计的预测准则 商用球墨铸铁和灰铁铸件。 最初的重点 将在球墨铸铁上。 收缩预测对此 一种重要的商用合金不仅由于 凝固行为的复杂性，但也由其极端 对冶金加工条件的敏感性。 因此， 发展实用新型的基本要求 设计软件是开发一个铸造动力学模型 铁的凝固，这实际上占的影响， 冶金加工的方式和顺序 固化 结合微观建模/热分析 将开发solificaction建模方法， 沿着一种算法，用于将固化模型应用于 在冷冻过程中根据以下参数估计体积变化： 能量和质量守恒，以及热力学 注意事项。 研究的最终目标是 制定一个综合的基于计算机的方法， 工艺控制、铸件设计优化和诊断 铸造缺陷，考虑到相互依赖的 冶金变量、成型因素和几何形状的影响 铸造质量。 铸件在工业中的设计过程包括 许多试验和错误，因为经验是唯一可用的 工具. 该项目涉及设计工具的开发 它结合了目前对冶金学的理解， 铸造金属和其他见解，从研究结果 项目 因此，可以更精确地设计部件， 减少了失败尝试的次数。

Research will develop numerical simulation-based shrinkage prediction criteria for the optimization of casting design of commercial ductile and gray iron castings. The initial focus will be on ductile iron. Shrinkage prediction for this important commercial alloy is complicated not only by the complexity of solidification behavior, but also by its extreme sensitivity to metallurgical processing conditions. Thus, an essential requirement for the development of practically useful design software is the development of a kinetic model of cast iron solidification which realistically accounts for the effects of metallurgical processing on mode and sequence of the solidification. A combined micro-modeling/thermal analysis approach to solificaction modeling will be developed, along with an algorithm for applying the solidifaction model to the estimation of volume changes during freezing on the basis of conservation of energy and mass, and thermodynamic considerations. The ultimate goal of the research is the development of an integrated computer-based methodology for process control, optimization of casting design, and diagnosis of casting defects which takes into account the interdependent effects of metallurgical variables, molding factors, and geometry on casting quality. Castings are designed in industry by a process that involves much trial and error, since experience is the only available tool. This project involves the development of a design tool which incorporates current understanding of the metallurgy of the cast metal and additional insights that result from the research project. Therefore, parts can be designed more precisely, reducing the number of failed attempts.