A low stress adaptive casting adjustment method and system

Abstract

The invention relates to the technical field of casting modeling, in particular to a low-stress adaptive casting adjustment method and system. The method comprises: collecting nitriding data of a target casting, obtaining a nitriding degree evaluation value of the target casting through processing, and judging whether the target casting has completed the nitriding treatment; collecting characterization data of the target casting that has completed the nitriding treatment, obtaining a residual stress evaluation value of the target casting through processing; obtaining the nitriding layer thickness of the target casting according to target matching, obtaining a cooling rate adjustment evaluation index of the target casting through comprehensive analysis, and adjusting the cooling system during the nitriding process. The invention provides a low-stress adaptive casting adjustment method and system, comprehensively analyzes the influence of the residual stress and nitriding layer thickness of the casting on adjusting the cooling rate of the casting, and adopts measures to adaptively adjust the cooling rate of the casting, thereby reducing internal defects of the casting and improving the quality of the casting.

Description

Technical Field

[0001] The invention relates to the technical field of casting modeling, and in particular to a low-stress self-adaptive casting adjustment method and system. Background Art

[0002] With the continuous development of industrial technology, the requirements for casting materials are increasing day by day, especially in high-precision, high-load and long-life mechanical equipment, which puts more stringent requirements on the strength, stiffness and stress level of casting materials. Traditional casting technology often finds it difficult to meet these conditions at the same time.

[0003] For example, the invention patent with publication number: CN115722632A is a method and device for low-stress casting of a weak-rigidity aluminum alloy box, including: a high-energy acoustic beam transducer, a plurality of high-energy acoustic beam transducers are provided; a casting sand mold, the casting sand mold has a cavity adapted to the box; a casting platform, the casting sand mold is placed on the casting platform, the high-energy acoustic beam transducer is arranged on the casting platform, and the transmitting end of the high-energy acoustic beam transducer is arranged toward the cavity. Obtain the parameters of the box; determine the casting process of the box according to the parameters of the box, and cast the box according to the casting process; determine the first control parameter according to the parameters of the box; after casting the box, control the high-energy acoustic beam transducer to emit a high-energy acoustic beam according to the first control parameter, and perform a first control on the box. In this way, the internal stress of the box can be reduced during the solidification and forming process of the box. Thereby, the box can be prevented from being deformed and cracked due to residual stress after solidification and forming.

[0004] For example, the invention patent with announcement number: CN103949587B is a casting mold preparation method for reducing the casting stress of large-scale nickel-based high-temperature alloy castings with sudden wall thickness in anti-gravity casting, the method is as follows: 1. Slurry the wax mold, sprinkle sand powder, dry it, and obtain the surface layer; 2. Slurry, then wrap the zirconium oxide fiber mesh on the surface of the surface layer obtained in step 1, and then sprinkle fine back sand and dry it; 3. Repeat step 2; 4. Slurry, sprinkle back sand, and obtain the back layer; 5. Dewax and roast; 6. Put the sand into the sand box, harden, and dry it.

[0005] However, in the process of implementing the technical solution of the invention in the embodiments of the present application, the present application discovered that the above technology has at least the following technical problems: the current traditional control methods include natural aging, thermal aging and vibration aging, which release internal stress by placing, heating or vibrating the casting for a long time, but their effects may not be significant enough and are time-consuming, and are not suitable for the needs of rapid production. Summary of the invention

[0006] In view of the deficiencies in the prior art, the present invention provides a low-stress adaptive casting adjustment method and system, which can effectively solve the problems involved in the above-mentioned background technology.

[0007] To achieve the above objectives, the present invention is implemented through the following technical solutions: The first aspect of the present invention provides a low-stress adaptive casting adjustment method, including: obtaining a poured casting, marking it as a target casting, collecting nitriding data of the target casting, obtaining a nitriding degree evaluation value of the target casting after processing, and judging whether the target casting has completed nitriding treatment according to the nitriding degree evaluation value of the target casting.

[0008] Characterization data of the target casting that has completed nitriding treatment is collected, and the residual stress evaluation value of the target casting is obtained after processing.

[0009] The nitriding layer thickness of the target casting is obtained by matching the nitriding degree evaluation value of the target casting, and the cooling rate adjustment evaluation index of the target casting is obtained by comprehensive analysis based on the residual stress evaluation value of the target casting. The cooling system in the nitriding process is adjusted according to the cooling rate adjustment evaluation index of the target casting.

[0010] As a further method, the nitriding data of the target casting includes the nitriding time of the target casting, the nitriding temperature of the target casting at the current time point and the nitrogen concentration of the target casting at the current time point.

[0011] As a further method, the nitriding degree evaluation value of the target casting is obtained through processing, and the specific process is: obtaining the basic data of the target casting, matching the preset values ​​of the nitriding parameters of the target casting, including the critical nitriding temperature and the critical nitrogen concentration, and obtaining the nitriding degree evaluation value of the target casting through comprehensive analysis based on the nitriding data of the target casting.

[0012] The basic data of the target casting includes the material and size of the target casting.

[0013] As a further method, the nitriding degree evaluation value of the target casting is used to determine whether the target casting has completed the nitriding treatment. The specific judgment process is: extracting a nitriding degree evaluation threshold from an adaptive system database, comparing the nitriding degree evaluation value of the target casting with the nitriding degree evaluation threshold, if the nitriding degree evaluation value of the target casting is higher than or equal to the nitriding degree evaluation threshold, then it is determined that the target casting has completed the nitriding treatment, if the nitriding degree evaluation value of the target casting is lower than the nitriding degree evaluation threshold, then it is determined that the target casting has not completed the nitriding treatment.

[0014] As a further method, the residual stress evaluation value of the target casting is obtained through processing, and the specific process is: the characterization data of the target casting includes the temperature of the target casting at each temperature collection point, the internal defect image of the target casting and the characterization image.

[0015] The deformation degree evaluation value of the target casting is obtained by processing the internal defect image and the characterization image of the target casting, and the residual stress evaluation value of the target casting is obtained by comprehensive analysis based on the temperature of the target casting at each temperature collection point. The residual stress evaluation value of the target casting is used to quantitatively evaluate the residual stress of the target casting and provide a basis for analyzing the cooling rate of the target casting.

[0016] As a further method, the processing obtains a deformation degree evaluation value of the target casting, and the specific process is: extracting the number of internal cracks and the maximum length of each crack from the internal defect image of the target casting, extracting the size data of the target casting from the characterization image of the target casting, and comparing the size data of the target casting with the original size data of the target casting, extracting the critical size deviation value, the critical crack number and the critical crack length from the adaptive system database, and comprehensively analyzing to obtain the deformation degree evaluation value of the target casting.

[0017] As a further method, the comprehensive analysis obtains the cooling rate adjustment evaluation index of the target casting. The specific analysis process is: according to the nitride layer thickness of the target casting and the residual stress evaluation value of the target casting, and the critical nitride layer thickness is extracted from the adaptive system database, the cooling rate adjustment evaluation index of the target casting is obtained by comprehensive analysis. The cooling rate adjustment evaluation index of the target casting is used to quantitatively evaluate the influence of the nitride layer thickness and residual stress of the target casting on the cooling rate of the target casting, and provide a basis for adjusting the cooling system.

[0018] As a further method, the cooling system in the nitriding process is adjusted according to the cooling rate adjustment evaluation index of the target casting. The specific process is: extracting the cooling rate adjustment evaluation index reference interval of the target casting from the adaptive system database, comparing the cooling rate adjustment evaluation index of the target casting with the cooling rate adjustment evaluation index reference interval of the target casting, if the cooling rate adjustment evaluation index of the target casting is higher or lower than the cooling rate adjustment evaluation index reference interval of the target casting, it indicates that the cooling system needs to be adjusted, if the cooling rate adjustment evaluation index of the target casting is in the cooling rate adjustment evaluation index reference interval of the target casting, it indicates that the cooling system does not need to be adjusted.

[0019] As a further method, the nitriding degree evaluation value of the target casting is specifically expressed as:

[0020] ;

[0021] in, Indicates the estimated value of the nitriding degree of the target casting, represents the nitriding temperature of the target casting at time t, t represents the time variable, Indicates the current time point. Indicates the time point when nitriding starts. represents the nitrogen concentration of the target casting at time t, represents the critical nitriding temperature, represents the critical nitrogen concentration, Indicates the influence factor of the nitriding degree corresponding to the preset nitriding temperature, Indicates the influencing factor of the nitriding degree corresponding to the preset nitrogen concentration.

[0022] A second aspect of the present invention provides a low stress adaptive casting adjustment system, characterized in that it includes: a casting nitriding treatment module, a casting stress assessment module, a cooling system adjustment module and an adaptive system database.

[0023] The casting nitriding treatment module is used to obtain the poured casting, mark it as the target casting, collect the nitriding data of the target casting, obtain the nitriding degree evaluation value of the target casting after processing, and judge whether the target casting has completed the nitriding treatment according to the nitriding degree evaluation value of the target casting.

[0024] The casting stress assessment module is used to collect characterization data of the target casting that has completed nitriding treatment, and obtain the residual stress assessment value of the target casting after processing.

[0025] The cooling system adjustment module is used to match the nitriding layer thickness of the target casting according to the nitriding degree evaluation value of the target casting, and to obtain the cooling rate adjustment evaluation index of the target casting according to the residual stress evaluation value of the target casting through comprehensive analysis, and to adjust the cooling system during the nitriding process according to the cooling rate adjustment evaluation index of the target casting.

[0026] Compared with the prior art, the embodiments of the present invention have at least the following advantages or beneficial effects:

[0027] (1) The present invention provides a low-stress adaptive casting adjustment method and system, comprehensively analyzes the influence of the residual stress of the casting and the thickness of the nitride layer on the cooling rate of the casting, and takes measures to adaptively adjust the cooling rate of the casting, thereby reducing internal defects of the casting and improving the mechanical properties and service life of the casting.

[0028] (2) The present invention comprehensively analyzes the effects of nitriding temperature, nitriding time and nitrogen concentration on the nitriding degree of castings. By rationally controlling these three parameters, an ideal nitriding effect can be obtained, the hardness and wear resistance of the castings can be improved, and the service life of the castings can be extended.

[0029] (3) The present invention comprehensively evaluates the deformation degree and internal quality of the casting by comprehensively considering three indicators: the number of internal cracks, the maximum length of each crack, and the change in casting size. It also analyzes the residual stress of the casting in combination with the temperature change of the casting. It can timely discover and solve the residual stress problem inside the casting, improve the quality and stability of the casting, and ensure its safe use. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] The present invention is further described using the accompanying drawings, but the embodiments in the accompanying drawings do not constitute any limitation to the present invention. A person skilled in the art can obtain other drawings based on the following drawings without creative work.

[0031] Figure 1 It is a schematic diagram of the method flow of the present invention.

[0032] Figure 2 It is a schematic diagram of system module connection of the present invention.

[0033] Figure 3 It is a schematic diagram of the functional relationship between the temperature change value and the residual stress evaluation value of the target casting involved in the embodiment of the present invention. DETAILED DESCRIPTION

[0034] The technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0035] Reference Figure 1 As shown, the first aspect of the present invention provides a low stress adaptive casting adjustment method, including: obtaining a poured casting, marking it as a target casting, collecting nitriding data of the target casting, obtaining a nitriding degree evaluation value of the target casting after processing, and judging whether the target casting has completed nitriding treatment according to the nitriding degree evaluation value of the target casting.

[0036] Specifically, the nitriding data of the target casting includes the nitriding time of the target casting, the nitriding temperature of the target casting at the current time point, and the nitrogen concentration of the target casting at the current time point.

[0037] It should be explained that in this embodiment, a nitrogen concentration monitor can be used to monitor the nitrogen concentration in the nitriding furnace in real time. These devices can accurately measure the nitrogen content and provide real-time data feedback. Temperature sensors are installed in the nitriding furnace to monitor the temperature in the furnace in real time. These sensors can measure and record temperature data to help control the nitriding process. At the same time, the time of the nitriding process can be tracked by setting up a time recording system. This can be a simple timer or a more complex automated system to record the start and end time of the nitriding process.

[0038] Furthermore, the nitriding degree evaluation value of the target casting is obtained through processing, and the specific process is: obtaining basic data of the target casting, matching to obtain preset values ​​of nitriding parameters of the target casting, including critical nitriding temperature and critical nitrogen concentration, and obtaining the nitriding degree evaluation value of the target casting through comprehensive analysis based on the nitriding data of the target casting.

[0039] The basic data of the target casting includes the material and size of the target casting.

[0040] It should be explained that the specific matching process for obtaining the preset values ​​of the nitriding parameters of the target casting is: combining the material and size to establish a joint label, and constructing a mapping set between the joint label and the preset values ​​of the nitriding parameters of the casting, inputting the material and size of the target casting, and obtaining the preset values ​​of the nitriding parameters corresponding to the target casting according to the mapping set.

[0041] It should be explained that different materials and sizes of castings have different absorption capacity and requirements for nitrogen. For example, high nitrogen steel castings may require more nitrogen injection to achieve the required nitride layer thickness and uniformity.

[0042] It should be understood that the evaluation value of the nitriding degree of the target casting is a quantitative evaluation data obtained by comprehensively analyzing the nitriding time of the target casting, the nitriding temperature of the target casting at the current time point and the nitrogen concentration, which is used to quantitatively evaluate the nitriding degree of the target casting and provide a basis for judging whether the nitriding of the target casting is completed.

[0043] In a specific embodiment, the numerical expression of the evaluation value of the nitriding degree of the target casting is:

[0044] ;

[0045] in, Indicates the estimated value of the nitriding degree of the target casting, represents the nitriding temperature of the target casting at time t, t represents the time variable, Indicates the current time point. Indicates the time point when nitriding starts. represents the nitrogen concentration of the target casting at time t, represents the critical nitriding temperature, represents the critical nitrogen concentration, Indicates the influence factor of the nitriding degree corresponding to the preset nitriding temperature, Indicates the influencing factor of the nitriding degree corresponding to the preset nitrogen concentration.

[0046] It should be explained that, when the nitriding time of the target casting is longer and the nitrogen concentration and the nitriding temperature are higher, the corresponding nitriding degree evaluation value is larger, indicating that the nitriding degree of the target casting is higher.

[0047] It should be explained that in this embodiment is the influencing factor of the nitriding degree corresponding to the preset nitriding temperature, The nitriding degree influencing factors corresponding to the preset nitrogen concentration respectively represent the numerical values ​​of the influencing degrees of the nitriding temperature and the nitrogen concentration unit values ​​on the nitriding degree of the target casting. When used, the nitriding degree influencing factors corresponding to the nitriding temperature and the nitriding degree influencing factors corresponding to the nitrogen concentration can be directly obtained from the adaptive system database. The corresponding relationship can be a pre-set mapping relationship. For example, the nitriding temperature and nitrogen concentration at the current time point respectively form a mapping set with the nitriding degree influencing factors corresponding to the nitriding temperature and nitrogen concentration preset in the adaptive system database. The real-time nitriding temperature and nitrogen concentration at the current time point are input into the mapping set to obtain the nitriding degree influencing factors corresponding to the nitriding temperature and the nitriding degree influencing factors corresponding to the nitrogen concentration. The mapping relationship can be one-to-one or many-to-one. The above influencing factors are all extracted from the adaptive system database, and the value range is between 0 and 1.

[0048] It needs to be explained that if the nitriding time is too short, the nitriding layer may not reach the expected thickness, resulting in limited improvement in the hardness and wear resistance of the casting. The extension of the nitriding time helps to thicken the nitriding layer. When the nitriding temperature is too low, the diffusion rate of nitrogen atoms slows down, resulting in insufficient thickness of the nitriding layer and reduced hardness. At the same time, low-temperature nitriding may also affect the nitrogen absorption capacity of the casting surface, making the nitriding effect unsatisfactory. High temperature helps to accelerate the diffusion of nitrogen atoms and the formation of the nitriding layer. When the nitrogen concentration is too low, the supply of nitrogen atoms is insufficient, resulting in a slowdown in the formation rate of the nitriding layer and insufficient thickness. At the same time, low concentrations of nitrogen may also affect the hardness and wear resistance of the nitriding layer. High concentrations of nitrogen help to accelerate the formation of the nitriding layer. Nitriding time, nitriding temperature and nitrogen concentration are key factors affecting the nitriding degree and effect of castings. By reasonably controlling these three parameters, an ideal nitriding effect can be obtained, the hardness and wear resistance of the casting can be improved, and the service life of the casting can be extended.

[0049] Furthermore, the process of judging whether the target casting has completed the nitriding treatment according to the nitriding degree evaluation value of the target casting is as follows: extracting a nitriding degree evaluation threshold from an adaptive system database, comparing the nitriding degree evaluation value of the target casting with the nitriding degree evaluation threshold; if the nitriding degree evaluation value of the target casting is higher than or equal to the nitriding degree evaluation threshold, judging that the target casting has completed the nitriding treatment; if the nitriding degree evaluation value of the target casting is lower than the nitriding degree evaluation threshold, judging that the target casting has not completed the nitriding treatment.

[0050] Characterization data of the target casting that has completed nitriding treatment is collected, and the residual stress evaluation value of the target casting is obtained after processing.

[0051] Specifically, the residual stress evaluation value of the target casting is obtained through processing, and the specific process is: the characterization data of the target casting includes the temperature of the target casting at each temperature collection point, the internal defect image of the target casting and the characterization image.

[0052] The deformation degree evaluation value of the target casting is obtained by processing the internal defect image and the characterization image of the target casting, and the residual stress evaluation value of the target casting is obtained by comprehensive analysis based on the temperature of the target casting at each temperature collection point. The residual stress evaluation value of the target casting is used to quantitatively evaluate the residual stress of the target casting and provide a basis for analyzing the cooling rate of the target casting.

[0053] In a specific embodiment, the numerical expression of the residual stress evaluation value of the target casting is:

[0054]

[0055] in, represents the residual stress evaluation value of the target casting, represents the temperature of the target casting at the rth temperature collection point, r represents the temperature of each temperature collection point, , h represents the total number of temperature collection points, Indicates the deformation degree evaluation value of the target casting, Indicates the casting residual stress influence factor corresponding to the preset temperature change, Indicates the casting residual stress influence factor corresponding to the preset deformation degree evaluation value of the target casting.

[0056] It should be explained that when the temperature change of the target casting is stronger, that is, the temperature difference is larger and the deformation degree evaluation value is larger, the corresponding residual stress evaluation value is larger, indicating that the residual stress of the target casting is larger.

[0057] It should be understood that if Figure 3As shown, curve a represents the relationship between the corresponding temperature change value when the deformation degree evaluation value of the target casting is 0.67 and the residual stress evaluation value of the target casting, curve b represents the relationship between the corresponding temperature change value when the deformation degree evaluation value of the target casting is 1.23 and the residual stress evaluation value of the target casting, and curve c represents the relationship between the corresponding temperature change value when the deformation degree evaluation value of the target casting is 2.12 and the residual stress evaluation value of the target casting.

[0058] It should be explained that the temperature change value .

[0059] It should be explained that, in this embodiment, the casting residual stress influence factor corresponding to the temperature change is set to 0.5, and the casting residual stress influence factor corresponding to the deformation degree evaluation value of the target casting is set to 0.2.

[0060] It should be explained that in this embodiment is the casting residual stress influencing factor corresponding to the preset temperature change, The casting residual stress influence factor corresponding to the preset deformation degree evaluation value of the target casting, respectively represents the numerical value of the influence degree of the temperature change and the deformation degree evaluation value unit value on the residual stress of the target casting, and the casting residual stress influence factor corresponding to the temperature change and the casting residual stress influence factor corresponding to the deformation degree evaluation value of the target casting can be directly obtained from the adaptive system database when used, and the corresponding relationship can be a pre-set mapping relationship, for example, the temperature and deformation degree evaluation value of each temperature acquisition point are respectively formed with the casting residual stress influence factor corresponding to the preset temperature and deformation degree evaluation value in the adaptive system database to form a mapping set, and the temperature and deformation degree evaluation value of each real-time temperature acquisition point are input into the mapping set to obtain the casting residual stress influence factor corresponding to the temperature change and the casting residual stress influence factor corresponding to the deformation degree evaluation value of the target casting, wherein the mapping relationship can be one-to-one or a many-to-one relationship. The above-mentioned influence factors are all extracted from the adaptive system database, and the value range is between 0 and 1.

[0061] It should be explained that, in the present embodiment, by comprehensively analyzing the temperature change and deformation degree of the casting, the residual stress problem existing inside the casting can be found in time, and corresponding measures can be taken to eliminate or homogenize. This helps to improve the quality and stability of the casting and extend its service life. According to the temperature change and deformation degree of the casting, the casting process parameters, such as pouring temperature, cooling rate, mold material, etc., can be optimized to reduce the generation of residual stress. At the same time, the structural design of the casting can also be improved to reduce the phenomenon of stress concentration and local accumulation of strain. Residual stress is one of the important reasons for the failure phenomena such as cracking and deformation of the casting. By comprehensively analyzing the temperature change and deformation degree of the casting, potential failure hazards can be found and eliminated in time to ensure the safe use of the casting. It is also possible to find and solve the residual stress problem existing inside the casting in time, improve the quality and stability of the casting, and ensure its safe use.

[0062] Furthermore, the processing obtains a deformation degree evaluation value of the target casting, and the specific process is: extracting the number of internal cracks and the maximum length of each crack from the internal defect image of the target casting, extracting the size data of the target casting from the characterization image of the target casting, and comparing the size data of the target casting with the original size data of the target casting, extracting the critical size deviation value, the critical crack number and the critical crack length from the adaptive system database, and comprehensively analyzing to obtain the deformation degree evaluation value of the target casting.

[0063] It should be understood that the deformation degree assessment value of the target casting is a quantitative assessment data obtained by comprehensively analyzing the dimensional deviation value, the number of cracks and the maximum crack length of the target casting, which is used to quantitatively assess the deformation degree of the target casting and provide a basis for assessing the residual stress of the target casting.

[0064] In a specific embodiment, the numerical expression of the deformation degree evaluation value of the target casting is:

[0065] ;

[0066] in, Indicates the deformation degree evaluation value of the target casting, , Indicates the size of the target casting, Indicates the number of internal cracks in the target casting, Indicates the original size of the target casting, represents the critical dimension deviation value, represents the critical internal crack number, Indicates the maximum length of the nth crack of the target casting, n represents the number of each crack, , m represents the total number of cracks, represents the critical crack length, Indicates the maximum length of the target casting, Indicates the ratio of the crack length of the target casting to the maximum length of the target casting. Indicates the influence factor of the target casting deformation degree corresponding to the preset size, Indicates the influence factor of the target casting deformation degree corresponding to the preset number of cracks, Indicates the influence factor of the target casting deformation degree corresponding to the preset maximum crack length.

[0067] It needs to be explained that As an activation function, it is always non-negative, so it is often used to predict non-negative values, such as probability values. This function can generate more clearly distinguished probability distributions. This gives it a certain advantage in classification tasks. At the same time, the smoothness of the Softplus function helps to improve numerical stability.

[0068] Table 1 Data example of the evaluation value of the deformation degree of the target casting

[0069] serial number Dimensional deviation (cubic centimeters) Number of internal cracks Deformation evaluation value 1 2 3 1.35 2 2 4 1.47 3 0 2 0.81 4 1 5 1.41 5 1 3 1.15

[0070] Table 2 Examples of data on the maximum length of each crack

[0071] serial number Length of the first crack (cm) Length of the second crack (cm) Length of the third crack (cm) Length of the 4th crack (cm) Length of the 5th crack (cm) 1 1.5 1.2 1 - - 2 1.8 1.5 1.2 1 - 3 2 1.5 - - - 4 2.5 2 1 1.5 0.5 5 1.2 1.5 1 - -

[0072] It should be explained that, as shown in Table 1, in this embodiment, the critical size deviation value is set to 1 cubic meter, the critical number of internal cracks is set to 2, the critical crack length is set to 2 centimeters, the target casting deformation degree influence factor corresponding to the size is set to 0.5, the target casting deformation degree influence factor corresponding to the number of cracks is set to 0.3, the target casting deformation degree influence factor corresponding to the maximum crack length is set to 0.2, the maximum length of the target casting is set to 100 centimeters, and Set to 1 / 100.

[0073] It should be explained that, as shown in Table 2, the five groups of data in this embodiment correspond to the numbers of internal cracks in Table 1 one by one, and represent the maximum length of each internal crack.

[0074] It should be explained that the size of the target casting refers to the volume of the target casting.

[0075] It should be explained that when the size change of the target casting is greater, the number of internal cracks is greater, and the internal cracks are longer, the corresponding deformation degree evaluation value is greater, indicating that the deformation degree of the target casting is greater.

[0076] It should be explained that in this embodiment The influence factor of the target casting deformation degree corresponding to the preset size, is the influencing factor of the target casting deformation degree corresponding to the preset number of cracks, The target casting deformation degree influence factor corresponding to the preset maximum crack length, respectively represents the numerical value of the influence degree of the casting size, the number of cracks and the maximum crack length unit value on the target casting deformation degree. When used, the target casting deformation degree influence factor corresponding to the size, the target casting deformation degree influence factor corresponding to the number of cracks and the target casting deformation degree influence factor corresponding to the maximum crack length can be directly obtained from the adaptive system database. The corresponding relationship can be a pre-set mapping relationship. For example, the size, number of cracks and maximum crack length of the target casting are respectively mapped with the target casting deformation degree influence factor corresponding to the preset casting size, number of cracks and maximum crack length in the adaptive system database to form a mapping set. The real-time casting size, number of cracks and maximum crack length are input into the mapping set to obtain the target casting deformation degree influence factor corresponding to the size, the target casting deformation degree influence factor corresponding to the number of cracks and the target casting deformation degree influence factor corresponding to the maximum crack length. The mapping relationship can be one-to-one or a many-to-one relationship. The above-mentioned influence factors are all extracted from the adaptive system database, and the value range is between 0 and 1.

[0077] It should be explained that castings can be irradiated with X-rays or Y-rays, and the change in radiation intensity caused by the defects when the rays propagate inside the castings can be used to form defect images, thereby evaluating the deformation inside the castings. X-ray detection can intuitively display the shape, size, number and distribution range of defects.

[0078] It should be explained that in this embodiment, when the number of cracks in the casting is large, it means that there are multiple defects inside the casting, and these defects may cause the casting to break or fail during use. At the same time, the increase in cracks may also reflect that the casting is subjected to greater stress or temperature changes during solidification, cooling or processing, thereby causing damage to the internal structure. When the length of the internal cracks in the casting is long, it may cause the casting to break when subjected to force, seriously affecting the safety of the casting. At the same time, long cracks may also cause stress concentration, causing the casting to deform or fail during use. A large casting size change value means that the casting is subjected to greater stress or temperature changes during solidification, cooling or processing, resulting in significant changes in the internal structure. This change may cause the casting to deform, crack, and other problems during use, seriously affecting the performance and safety of the casting. By comprehensively considering the three indicators of the number of internal cracks, the maximum length of each crack, and the casting size change value, the degree of deformation and internal quality of the casting can be comprehensively evaluated. This helps to promptly discover potential problems and take corresponding repair measures to ensure the performance and safety of the casting.

[0079] The nitriding layer thickness of the target casting is obtained by matching the nitriding degree evaluation value of the target casting, and the cooling rate adjustment evaluation index of the target casting is obtained by comprehensive analysis based on the residual stress evaluation value of the target casting. The cooling system in the nitriding process is adjusted according to the cooling rate adjustment evaluation index of the target casting.

[0080] Specifically, the comprehensive analysis obtains the cooling rate adjustment evaluation index of the target casting. The specific analysis process is: according to the nitride layer thickness of the target casting and the residual stress evaluation value of the target casting, and the critical nitride layer thickness is extracted from the adaptive system database, and the cooling rate adjustment evaluation index of the target casting is obtained by comprehensive analysis. The cooling rate adjustment evaluation index of the target casting is used to quantitatively evaluate the influence of the nitride layer thickness and residual stress of the target casting on the cooling rate of the target casting, and provide a basis for adjusting the cooling system.

[0081] In a specific embodiment, the numerical expression of the cooling rate adjustment evaluation index of the target casting is:

[0082] ;

[0083] in, represents the cooling rate adjustment evaluation index of the target casting, Indicates the nitriding layer thickness of the target casting, represents the critical nitride layer thickness, represents the residual stress evaluation value of the target casting, Indicates the cooling rate adjustment influence factor of the target casting corresponding to the preset nitriding layer thickness, Indicates the cooling rate adjustment influence factor of the target casting corresponding to the preset residual stress evaluation value.

[0084] It needs to be explained that the thicker the nitride layer of the target casting, the longer the cooling time. When the residual stress evaluation value of the target casting is larger, the cooling speed is lower, indicating that the cooling rate of the target casting is smaller, that is, the corresponding cooling rate adjustment evaluation index of the target casting is larger, indicating that the nitride layer thickness and residual stress evaluation value of the target casting have a greater influence on the cooling rate.

[0085] It should be explained that in this embodiment Indicates the cooling rate adjustment influence factor of the target casting corresponding to the preset nitriding layer thickness, The cooling rate adjustment influence factor of the target casting corresponding to the preset residual stress evaluation value is represented, and the numerical values ​​of the influence degree of the unit value of the nitriding layer thickness and the residual stress evaluation value on the cooling rate of the target casting are respectively represented. When used, the cooling rate adjustment influence factor of the target casting corresponding to the nitriding layer thickness and the cooling rate adjustment influence factor of the target casting corresponding to the residual stress evaluation value can be directly obtained from the adaptive system database, and the corresponding relationship can be a pre-set mapping relationship. For example, the nitriding layer thickness and the residual stress evaluation value of the target casting are respectively formed with the cooling rate adjustment influence factors corresponding to the nitriding layer thickness and the residual stress evaluation value preset in the adaptive system database to form a mapping set, and the real-time nitriding layer thickness and the residual stress evaluation value of the target casting are input into the mapping set to obtain the cooling rate adjustment influence factor of the target casting corresponding to the nitriding layer thickness and the cooling rate adjustment influence factor of the target casting corresponding to the residual stress evaluation value, wherein the mapping relationship can be one-to-one or a many-to-one relationship. The above-mentioned influence factors are all extracted from the adaptive system database, and the value range is between 0 and 1.

[0086] It should be explained that the process of obtaining the nitriding layer thickness of the target casting by matching the nitriding degree evaluation value of the target casting is: constructing a mapping set of the nitriding degree evaluation value of the target casting and its nitriding layer thickness, inputting the real-time nitriding degree evaluation value of the target casting, and obtaining the nitriding layer thickness corresponding to the target casting according to the mapping set matching.

[0087] Furthermore, the cooling system in the nitriding process is adjusted according to the cooling rate adjustment evaluation index of the target casting, and the specific process is: extracting the cooling rate adjustment evaluation index reference interval of the target casting from the adaptive system database, comparing the cooling rate adjustment evaluation index of the target casting with the cooling rate adjustment evaluation index reference interval of the target casting, if the cooling rate adjustment evaluation index of the target casting is higher or lower than the cooling rate adjustment evaluation index reference interval of the target casting, it indicates that the cooling system needs to be adjusted, if the cooling rate adjustment evaluation index of the target casting is in the cooling rate adjustment evaluation index reference interval of the target casting, it indicates that the cooling system does not need to be adjusted.

[0088] In a specific embodiment, the cooling rate of the casting can be adjusted by improving the layout of the cooling water circuit, increasing or decreasing the cooling water flow rate, etc. The specific steps are as follows: first, according to the diagnosis results and the adjustment strategy, the cooling system is adjusted accordingly. For castings whose cooling rate adjustment index is higher than the index interval, the difference is calculated, and the corresponding cooling water flow rate that needs to be reduced is obtained according to the difference matching, and the cooling rate is reduced by reducing the cooling water flow rate. For castings whose cooling rate adjustment index is lower than the index interval, the difference is calculated, and the corresponding cooling water flow rate that needs to be increased is obtained according to the difference matching, and then the cooling rate is accelerated by increasing the cooling water flow rate. At the same time, during the adjustment process, the cooling rate and temperature distribution of the casting are continuously monitored to ensure that the adjustment effect meets expectations. Finally, according to the monitoring results, the adjustment strategy is adjusted and optimized as necessary to ensure the stable improvement of the quality of the casting.

[0089] It needs to be explained that it is necessary to ensure that the cooling water circuit is designed reasonably to achieve uniform cooling and avoid local overheating or overcooling.

[0090] It should be explained that, in this embodiment, by reasonably adjusting the cooling rate, it is possible to avoid excessive internal stress and deformation of the casting during the cooling process, thereby improving the dimensional stability and shape accuracy of the casting. At the same time, a uniform cooling rate helps to reduce defects (such as pores, slag inclusions, etc.) inside the casting and improve the mechanical properties and service life of the casting. By analyzing the residual stress of the casting and the thickness of the nitrided layer, the casting process parameters can be optimized to achieve a more uniform cooling rate and higher casting quality. Furthermore, a reasonable cooling rate helps to shorten the cooling time of the casting, thereby improving production efficiency. At the same time, reducing internal defects of the casting and improving the quality of the casting can also reduce subsequent processing and repair work, further reducing production costs.

[0091] Reference Figure 2 As shown, the second aspect of the present invention provides a low stress adaptive casting adjustment system, characterized in that it includes: a casting nitriding treatment module, a casting stress assessment module, a cooling system adjustment module and an adaptive system database.

[0092] The casting nitriding treatment module is used to obtain the poured casting, mark it as the target casting, collect the nitriding data of the target casting, obtain the nitriding degree evaluation value of the target casting after processing, and judge whether the target casting has completed the nitriding treatment according to the nitriding degree evaluation value of the target casting.

[0093] The casting stress assessment module is used to collect characterization data of the target casting that has completed nitriding treatment, and obtain the residual stress assessment value of the target casting after processing.

[0094] The cooling system adjustment module is used to match the nitriding layer thickness of the target casting according to the nitriding degree evaluation value of the target casting, and to obtain the cooling rate adjustment evaluation index of the target casting according to the residual stress evaluation value of the target casting through comprehensive analysis, and to adjust the cooling system during the nitriding process according to the cooling rate adjustment evaluation index of the target casting.

[0095] In a specific embodiment, the adaptive system database is used to store relevant data in the nitriding process of the target casting, including critical nitriding temperature and critical nitrogen concentration, nitriding degree evaluation threshold, cooling rate adjustment influence factor of the target casting corresponding to the nitriding layer thickness and cooling rate adjustment influence factor of the target casting corresponding to the residual stress evaluation value, and the data extracted from the adaptive system database in the above embodiment, which can be collected by using a casting alloy solidification characteristic detector for heat transfer, linear shrinkage, thermal cracking and stress and other characteristic parameters of casting materials such as aluminum alloys during the solidification process. Through these real-time data, the form and characteristics of the parameters in the casting process design process can be analyzed. It is also possible to use sensors (such as tension and pressure sensors) to form a stress frame with the casting after pouring the molten metal to measure key parameters such as thermal stress.

[0096] The above contents are merely examples and explanations of the structure of the present invention. The technicians in this technical field may make various modifications or additions to the specific embodiments described or replace them in a similar manner. As long as they do not deviate from the structure of the invention or exceed the scope defined by the claims, they should all fall within the protection scope of the present invention.

Claims

1. A low stress adaptive casting adjustment method, characterized in that: include: Obtaining a poured casting, marking it as a target casting, collecting nitriding data of the target casting, obtaining a nitriding degree evaluation value of the target casting after processing, and judging whether the target casting has completed nitriding treatment according to the nitriding degree evaluation value of the target casting; The characterization data of the target casting that has completed the nitriding treatment are collected, and the residual stress evaluation value of the target casting is obtained through processing; The nitriding layer thickness of the target casting is obtained by matching the nitriding degree evaluation value of the target casting, and the cooling rate adjustment evaluation index of the target casting is obtained by comprehensive analysis according to the residual stress evaluation value of the target casting, and the cooling system in the nitriding process is adjusted according to the cooling rate adjustment evaluation index of the target casting; The nitriding data of the target casting include the nitriding time of the target casting, the nitriding temperature of the target casting at the current time point, and the nitrogen concentration of the target casting at the current time point; The nitriding degree evaluation value of the target casting is obtained through processing, and the specific process is: obtaining basic data of the target casting, matching to obtain preset values ​​of nitriding parameters of the target casting, including critical nitriding temperature and critical nitrogen concentration, and obtaining the nitriding degree evaluation value of the target casting through comprehensive analysis based on the nitriding data of the target casting; The basic data of the target casting, including the material and size of the target casting; The residual stress evaluation value of the target casting is obtained by processing, and the specific process is: the characterization data of the target casting includes the temperature of the target casting at each temperature collection point, the internal defect image of the target casting and the characterization image; The deformation degree evaluation value of the target casting is obtained by processing the internal defect image and the characterization image of the target casting, and the residual stress evaluation value of the target casting is obtained by comprehensive analysis according to the temperature of the target casting at each temperature collection point. The residual stress evaluation value of the target casting is used to quantitatively evaluate the residual stress of the target casting and provide a basis for analyzing the cooling rate of the target casting; The processing obtains a deformation degree evaluation value of the target casting, and the specific process is: extracting the number of internal cracks and the maximum length of each crack from the internal defect image of the target casting, extracting the size data of the target casting from the characterization image of the target casting, and comparing the size data of the target casting with the original size data of the target casting, extracting the critical size deviation value, the critical crack number and the critical crack length from the adaptive system database, and comprehensively analyzing to obtain the deformation degree evaluation value of the target casting; The comprehensive analysis obtains the cooling rate adjustment evaluation index of the target casting, and the specific analysis process is: according to the nitriding layer thickness of the target casting and the residual stress evaluation value of the target casting, and extracting the critical nitriding layer thickness from the adaptive system database, the cooling rate adjustment evaluation index of the target casting is obtained by comprehensive analysis, and the cooling rate adjustment evaluation index of the target casting is used to quantitatively evaluate the influence of the nitriding layer thickness and residual stress of the target casting on the cooling rate of the target casting, so as to provide a basis for adjusting the cooling system; The specific numerical expression of the evaluation value of the nitriding degree of the target casting is: ； in, Indicates the estimated value of the nitriding degree of the target casting, represents the nitriding temperature of the target casting at time t, t represents the time variable, Indicates the current time point. Indicates the time point when nitriding starts. represents the nitrogen concentration of the target casting at time t, represents the critical nitriding temperature, represents the critical nitrogen concentration, Indicates the influence factor of the nitriding degree corresponding to the preset nitriding temperature, Indicates the nitriding degree influence factor corresponding to the preset nitrogen concentration; The numerical expression of the residual stress evaluation value of the target casting is: ； in, represents the residual stress evaluation value of the target casting, represents the temperature of the target casting at the rth temperature collection point, r represents the temperature of each temperature collection point, , h represents the total number of temperature collection points, Indicates the deformation degree evaluation value of the target casting, Indicates the casting residual stress influence factor corresponding to the preset temperature change, Indicates the casting residual stress influence factor corresponding to the preset deformation degree evaluation value of the target casting; The numerical expression of the deformation degree evaluation value of the target casting is: ； in, Indicates the deformation degree evaluation value of the target casting, , Indicates the size of the target casting, Indicates the number of internal cracks in the target casting, Indicates the original size of the target casting, represents the critical dimension deviation value, represents the critical internal crack number, Indicates the maximum length of the nth crack of the target casting, n represents the number of each crack, , m represents the total number of cracks, represents the critical crack length, Indicates the maximum length of the target casting, Indicates the ratio of the crack length of the target casting to the maximum length of the target casting. Indicates the influence factor of the target casting deformation degree corresponding to the preset size, Indicates the influence factor of the target casting deformation degree corresponding to the preset number of cracks, Indicating the influence factor of the target casting deformation degree corresponding to the preset maximum crack length; The numerical expression of the cooling rate adjustment evaluation index of the target casting is: ； in, represents the cooling rate adjustment evaluation index of the target casting, Indicates the nitride layer thickness of the target casting, represents the critical nitride layer thickness, represents the residual stress evaluation value of the target casting, Indicates the cooling rate adjustment influence factor of the target casting corresponding to the preset nitriding layer thickness, Indicates the cooling rate adjustment influence factor of the target casting corresponding to the preset residual stress evaluation value.

2. A low stress adaptive casting adjustment method according to claim 1, characterized in that: The specific judgment process of judging whether the target casting has completed the nitriding treatment according to the nitriding degree evaluation value of the target casting is as follows: A nitriding degree assessment threshold is extracted from the adaptive system database, and the nitriding degree assessment value of the target casting is compared with the nitriding degree assessment threshold. If the nitriding degree assessment value of the target casting is higher than or equal to the nitriding degree assessment threshold, it is judged that the target casting has completed the nitriding treatment. If the nitriding degree assessment value of the target casting is lower than the nitriding degree assessment threshold, it is judged that the target casting has not completed the nitriding treatment.

3. The low stress adaptive casting adjustment method according to claim 1, characterized in that: The cooling system in the nitriding process is adjusted according to the cooling rate adjustment evaluation index of the target casting, and the specific process is: A reference interval of the cooling rate adjustment evaluation index of the target casting is extracted from the adaptive system database, and the cooling rate adjustment evaluation index of the target casting is compared with the reference interval of the cooling rate adjustment evaluation index of the target casting. If the cooling rate adjustment evaluation index of the target casting is higher or lower than the reference interval of the cooling rate adjustment evaluation index of the target casting, it indicates that the cooling system needs to be adjusted; if the cooling rate adjustment evaluation index of the target casting is within the reference interval of the cooling rate adjustment evaluation index of the target casting, it indicates that the cooling system does not need to be adjusted.

4. A system for a low stress adaptive casting adjustment method according to any one of claims 1 to 3, characterized in that: include: Casting nitriding treatment module, casting stress assessment module, cooling system adjustment module and adaptive system database; A casting nitriding treatment module is used to obtain a poured casting, mark it as a target casting, collect nitriding data of the target casting, obtain a nitriding degree evaluation value of the target casting after processing, and judge whether the target casting has completed nitriding treatment according to the nitriding degree evaluation value of the target casting; A casting stress assessment module is used to collect characterization data of a target casting that has completed nitriding treatment, and obtain a residual stress assessment value of the target casting after processing; The cooling system adjustment module is used to match the nitriding layer thickness of the target casting according to the nitriding degree evaluation value of the target casting, and to obtain the cooling rate adjustment evaluation index of the target casting according to the residual stress evaluation value of the target casting through comprehensive analysis, and to adjust the cooling system during the nitriding process according to the cooling rate adjustment evaluation index of the target casting.

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