Residual stress control system and method based on metal casting

Abstract

The invention relates to the technical field of metal processing and casting, and specifically discloses a residual stress control system and method based on metal casting molding. The system collects simulation process parameters of the metal casting molding process and basic parameters of components to be cast, and analyzes the residual stress risk assessment value of the metal casting molding process through big data, which is helpful to identify and solve potential casting problems from the root, and provide strong data support for subsequent casting optimization work. By evaluating the process optimization index of the metal casting molding process after executing the process optimization set of the metal casting molding process, the actual effect brought by the process optimization is quantified, and a basis is provided for subsequent adjustment and improvement. By adjusting the process optimization set of the metal casting molding process, the process adjustment index of the metal casting molding process is determined, and finally the intelligent control of the residual stress of the metal casting molding process is adjusted and feedback is given, so that the metal casting molding process meets the actual casting requirements.

Description

Technical Field

[0001] The invention relates to the technical field of metal processing and casting, and in particular to a residual stress control system and method based on metal casting. Background Art

[0002] In the field of modern manufacturing, the residual stress problem in the metal casting process has always been a major technical challenge. The uneven distribution of this stress often causes the metal to suffer accidental damage such as fatigue fracture and brittle failure during use, which in turn has a serious impact on the quality and life expectancy of the product. In order to cope with this problem, the existing technology has achieved real-time monitoring and effective control of the residual stress in the metal casting process by integrating core modules such as data acquisition equipment and data processing platforms, providing a solid technical guarantee for improving product quality and extending product service life.

[0003] For example, the invention patent with announcement number CN105798301B announces a stress relief method for TC4 titanium alloy additively manufactured components based on dual electron beams, specifically refers to a stress relief control method for large-size TC4 titanium alloy additively manufactured components based on dual electron beams, which involves the field of additive manufacturing technology. It consists of step A, which is the establishment and correction of a dual electron beam temperature field model, and step B, which is the use of dual electron beams for wire-filling additive manufacturing. Dual electron beam technology is used to control phase change in real time during the additive manufacturing process, and the stress relief of large-size TC4 titanium alloy additively manufactured components is achieved by controlling phase change to improve the overall plasticity of the components, providing a new method for solving the key technical problems in the manufacture of large-size TC4 titanium alloy additively manufactured components.

[0004] For example, the invention patent with announcement number CN117464008B announces a processing system for residual stress toughened metal ceramic tools, the main material of the tool is TiCN; the processing system includes a first preparation module, a performance testing module, a second preparation module and a parameter adjustment module; the first preparation module is used to perform preliminary processing on the material to obtain a tool substrate with good comprehensive performance, the performance testing module is used to test the comprehensive performance of the tool substrate, and the second preparation module is used to perform further residual stress and subsequent processing on the tool substrate to complete the final tool manufacturing.

[0005] However, in the process of implementing the embodiments of the present application, it was found that the above-mentioned technology has at least the following technical problems: when analyzing and processing the residual stress in the metal casting molding process, the prior art only relies on the same adjustment for processing, resulting in the residual stress control in the metal casting molding process under different production requirements cannot achieve the expected effect. Summary of the invention

[0006] In view of the deficiencies in the prior art, the present invention provides a residual stress control system and method based on metal casting, 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: In the first aspect, the present invention provides a residual stress control system based on metal casting molding, including: a risk assessment module, which is used to collect simulation process parameters of the metal casting molding process and basic parameters of the components to be cast through a simulation process of metal casting molding, and thereby analyze the residual stress risk assessment value of the metal casting molding process based on big data; a process optimization module, which is used to compare the residual stress risk assessment value of the metal casting molding process with the residual stress risk assessment threshold, and if the residual stress risk assessment value of the metal casting molding process is less than or equal to the residual stress risk assessment threshold, then execute the casting feedback module, and if the residual stress risk assessment value of the metal casting molding process is greater than the residual stress risk assessment threshold, then match and execute the metal casting. A process optimization set for the forming process is formed, thereby evaluating the process optimization index of the metal casting forming process; a process adjustment module is used to compare the process optimization index of the metal casting forming process with the process optimization threshold. If the process optimization index of the metal casting forming process is greater than the process optimization threshold, the simulation process parameters of the metal casting forming process are updated and the casting feedback module is executed. If the process optimization index of the metal casting forming process is less than or equal to the process optimization threshold, the process optimization set of the metal casting forming process is adjusted to determine the process adjustment index of the metal casting forming process, thereby adjusting and feeding back the intelligent control of residual stress in the metal casting forming process; a casting feedback module is used to collect the simulation process parameters of the metal casting forming process and feed back the simulation process parameters of the metal casting forming process.

[0008] As a further solution, if the residual stress risk assessment value of the metal casting molding process is less than or equal to the residual stress risk assessment threshold, a parameter preparation setting set of the metal casting molding process is generated, the simulation process parameters of the metal casting molding process are transmitted to the parameter preparation setting set of the metal casting molding process, and the parameter preparation setting set of the metal casting molding process is fed back in the form of a log, thereby completing the feedback of the simulation process parameters of the metal casting molding process.

[0009] As a further solution, the matching and execution of the process optimization set of the metal casting molding process, the specific matching process is: the residual stress risk assessment value of the metal casting molding process is ratio-processed with the residual stress risk assessment threshold to obtain the residual stress risk assessment proportional coefficient of the metal casting molding process; the residual stress risk assessment proportional coefficient of the metal casting molding process is matched with the process optimization set corresponding to each residual stress risk assessment proportional coefficient interval stored in the casting database, thereby obtaining and simulating the execution of the process optimization set of the metal casting molding process, and updating the residual stress risk assessment value of the metal casting molding process, which is marked as the updated residual stress risk assessment value of the metal casting molding process.

[0010] As a further solution, if the process optimization index of the metal casting molding process is greater than the process optimization threshold, a parameter preparation configuration set of the metal casting molding process is generated, the simulation process parameters of the metal casting molding process are updated based on the process optimization set of the metal casting molding process, and the updated simulation process parameters of the metal casting molding process are transmitted to the parameter preparation configuration set of the metal casting molding process, and the parameter preparation configuration set of the metal casting molding process is fed back in the form of a log, thereby completing the feedback of the simulation process parameters of the metal casting molding process.

[0011] As a further solution, the specific adjustment feedback process is as follows: comparing the process adjustment index of the metal casting molding process with the process adjustment threshold; if the process adjustment index of the metal casting molding process is less than or equal to the process adjustment threshold, performing difference processing on the process adjustment threshold and the process adjustment index of the metal casting molding process to obtain the process adjustment difference of the metal casting molding process, matching the difference with the parameter adjustment set corresponding to each process adjustment difference interval stored in the casting database to obtain the parameter adjustment set of the metal casting molding process, thereby adjusting the process optimization set of the metal casting molding process until the process adjustment index of the metal casting molding process is greater than the process adjustment threshold; if the metal casting When the process adjustment index of the forming process is greater than the process adjustment threshold, adjustment parameters for adjusting the process optimization set of the metal casting forming process are collected, and the process optimization set of the metal casting forming process is adjusted based on the process optimization set of the metal casting forming process and the adjustment parameters, thereby updating the simulation process parameters of the metal casting forming process, generating a pre-production parameter preparation set of the metal casting forming process, transmitting the updated simulation process parameters of the metal casting forming process to the pre-production parameter preparation set of the metal casting forming process, and feeding back the pre-production parameter preparation set of the metal casting forming process in the form of a log, thereby completing the adjustment feedback of the intelligent control of residual stress in the metal casting forming process.

[0012] The second aspect of the present invention provides a method for the residual stress control system based on metal casting, comprising: S1. Through the simulation process of metal casting, the simulation process parameters of the metal casting process and the basic parameters of the components to be cast are collected, and the residual stress risk assessment value of the metal casting process is analyzed by big data; S2. The residual stress risk assessment value of the metal casting process is compared with the residual stress risk assessment threshold. If the residual stress risk assessment value of the metal casting process is less than or equal to the residual stress risk assessment threshold, S4 is executed; if the residual stress risk assessment value of the metal casting process is greater than the residual stress risk assessment threshold, the metal casting process is matched and executed. process optimization set, thereby evaluating the process optimization index of the metal casting molding process; S3. comparing the process optimization index of the metal casting molding process with the process optimization threshold; if the process optimization index of the metal casting molding process is greater than the process optimization threshold, updating the simulation process parameters of the metal casting molding process and executing S4; if the process optimization index of the metal casting molding process is less than or equal to the process optimization threshold, adjusting the process optimization set of the metal casting molding process, determining the process adjustment index of the metal casting molding process, thereby adjusting and feeding back the intelligent control of residual stress in the metal casting molding process; S4. collecting the simulation process parameters of the metal casting molding process, and feeding back the simulation process parameters of the metal casting molding process.

[0013] Compared with the prior art, the embodiments of the present invention have at least the following advantages or beneficial effects:

[0014] (1) The present invention provides a residual stress control system and method based on metal casting molding, collects simulation process parameters of the metal casting molding process and basic parameters of the components to be cast, analyzes the residual stress risk assessment value of the metal casting molding process through big data, and obtains the process optimization set of the metal casting molding process, which is helpful to identify potential casting problems from the root and provide strong data support for subsequent casting optimization work. By evaluating the process optimization index of the metal casting molding process after executing the process optimization set of the metal casting molding process, the actual effect brought by the process optimization is quantified, which provides a basis for subsequent adjustment and improvement. By adjusting the process optimization set of the metal casting molding process, the process adjustment index of the metal casting molding process is determined, and finally the intelligent control of the residual stress of the metal casting molding process is adjusted and feedback is given, so that the metal casting molding process meets the actual casting requirements. Through continuous iteration and adjustment, the refined and intelligent control of the metal casting molding process is realized, and the production efficiency and product quality of the metal casting molding process are improved.

[0015] (2) The present invention executes a process optimization set for the metal casting molding process, and after the execution, conducts an in-depth analysis of the parameters of the quenching stage in the metal casting molding process. It can accurately evaluate the effectiveness of the process optimization set in making subtle adjustments to the metal casting molding process. At the same time, the performance of the quenching stage can reflect the quality and effectiveness of the processes in each stage before the quenching stage, thus becoming an important window for measuring the overall process level. This method also effectively reduces the complexity of data processing work and improves the efficiency of parameter analysis of the metal casting molding process.

[0016] (3) In view of the fact that the process optimization set of the metal casting molding process can no longer meet the needs of the current metal casting molding process, the process optimization set of the metal casting molding process is comprehensively adjusted through the parameter adjustment set of the metal casting molding process. Therefore, the present invention executes the parameter adjustment set of the metal casting molding process and analyzes the parameters in the overall metal casting molding process after the execution is completed. It can timely discover and solve potential quality problems, thereby intelligently selecting the optimal parameters of the metal casting molding process to ensure that the metal casting products always meet the quality requirements. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] 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.

[0018] Figure 1 It is a schematic diagram of system module connection of the present invention.

[0019] Figure 2 The figure is a schematic flow chart of the method steps of the present invention.

[0020] Figure 3 It is a schematic diagram of the machine tool mold involved in the present invention.

[0021] Figure numerals: 1, temperature measurement point; 2, temperature measurement point; 3, temperature measurement point; 4, vertical distance; 5, vertical distance. DETAILED DESCRIPTION

[0022] 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.

[0023] Reference Figure 1As shown, the first aspect of the present invention provides a residual stress control system based on metal casting, including: a risk assessment module, a process optimization module, a process adjustment module and a casting feedback module.

[0024] The first aspect of the present invention provides a residual stress control system based on metal casting, which also includes a casting database, which is used to store a reference average pouring speed, a reference temperature gradient discrete value, a process optimization set corresponding to each residual stress risk assessment proportional coefficient interval, a reference flow discrete value, a reference average temperature, a weight factor corresponding to an updated residual stress risk assessment value, a reference average pouring speed, a reference flow discrete value, a reference total time, a parameter adjustment set corresponding to each process adjustment difference interval, simulation process parameters of the metal casting forming process corresponding to the basic parameters of each component to be cast, a residual stress risk assessment threshold and a process optimization threshold.

[0025] The risk assessment module is connected to the process optimization module, the process optimization module is connected to the process adjustment module and the casting feedback module, the process adjustment module is connected to the casting feedback module, and the risk assessment module, process optimization module, process adjustment module and casting feedback module are all connected to the casting database.

[0026] It should be explained that this embodiment analyzes the residual stress of the metal casting process by simulating the casting stage of the metal casting process. The casting stage is divided into a pouring stage and a cooling stage. The pouring stage refers to melting the metal powder containing the key materials into molten metal and pouring the molten metal into the machine tool mold. The cooling stage includes a chilling stage, a stable cooling stage, a slow cooling stage, and a final cooling and room temperature stage. In the chilling stage, after the molten metal is poured into the machine tool mold, the machine tool mold and the cooling device (such as a water cooling device) will quickly cool the molten metal to make it solidify quickly to form a harder primary solidification shell. This rapid cooling process It is called "quenching". The main purpose of chilling is to increase the cooling rate of the casting, thereby refining the structure of the casting, improving its hardness and strength, and reducing the occurrence of internal defects. The simulation process is all in the metal casting molding process simulation analysis platform. The metal casting molding process simulation analysis platform has diversified functions such as data collection and data processing. It simulates the metal casting molding process by receiving the simulation process parameters of the metal casting molding process. During the simulation process, the metal casting molding process simulation analysis platform generates temperature field data, velocity field data, defect data and stress field data of the metal casting molding process, providing comprehensive and detailed simulation information.

[0027] It needs to be further explained that the process optimization set of the metal casting molding process is a subtle adjustment of the simulation process parameters of the metal casting molding process, in which a few parameters are adjusted, and the parameter adjustment set of the metal casting molding process is a comprehensive adjustment of the process optimization set of the metal casting molding process, in which the parameters are significantly adjusted.

[0028] The risk assessment module is used to collect simulation process parameters of the metal casting process and basic parameters of the components to be cast through the simulation process of metal casting, thereby performing big data analysis on the residual stress risk assessment value of the metal casting process.

[0029] The simulation process parameters of the above-mentioned metal casting forming process are matched from the casting database according to the basic parameters of the components to be cast. The casting database stores the simulation process parameters of the metal casting forming process corresponding to the basic parameters of each component to be cast. The corresponding rules and values ​​are formulated by the metal casting forming process administrator based on historical work experience. For example, the basic parameters of the components to be cast include: the copper content of the molten metal is 3.9%, the iron content of the molten metal is 0.9%, the tensile strength of the components to be cast is not less than 300 MPa, and the The impact toughness value of the cast component is not less than 20 joules. The simulation process parameters corresponding to the basic parameters queried from the casting database include: the silicon content of the molten metal is 7%, the magnesium content of the molten metal is 0.4%, the copper content of the molten metal is 3.9%, the iron content of the molten metal is 0.9%, the pouring temperature is 700 degrees Celsius, the pouring speed is 10 kg of molten metal flowing through the gate per second, the machine tool mold temperature is 250 degrees Celsius, the casting pressure is 100 MPa, the chilling water temperature is -30 degrees Celsius, the chilling time is 5 seconds, and the chilling pressure is 0.5 MPa.

[0030] The above-mentioned big data analysis of the residual stress risk assessment value of the metal casting molding process refers to analyzing the residual stress risk assessment value of the metal casting molding process through the expression of the residual stress risk assessment value of the metal casting molding process.

[0031] Specifically, the residual stress risk assessment value of the metal casting molding process, in this embodiment, is obtained by comprehensive analysis of the average pouring speed of the molten metal in the metal casting molding process, the temperature gradient discrete value of the temperature measurement point in the metal casting molding process, and the content of each key material in the molten metal in the metal casting molding process, and is used to analyze the value of the residual stress risk degree of the metal casting molding process. The specific analysis process is:

[0032] ;

[0033] It is the average pouring speed of the molten metal in the metal casting process, which refers to the average volume of the molten metal flowing through the gate per unit time.

[0034] It is the discrete value of the temperature gradient of the temperature measurement point in the metal casting process, which refers to the discrete degree of the temperature difference between adjacent temperature measurement points in the metal casting process.

[0035] It is the content of the nth key material in the molten metal in the metal casting process, which refers to the content of materials that have an important influence on the performance of the casting. These key materials usually include alloy elements, impurity elements and compounds that may have a significant impact on the performance of the casting. For example, in aluminum alloy castings, elements such as silicon, magnesium and copper are key materials. Their content directly affects the strength, hardness, toughness and corrosion resistance of the casting. For each specific casting, the type and content of key materials need to be accurately determined and controlled according to the design requirements, use environment and process conditions.

[0036] It is the reference average pouring speed preset in the casting database, which represents the reference value of the average pouring speed of the molten metal in the metal casting process.

[0037] It is the reference temperature gradient discrete value preset in the casting database, which represents the reference value of the temperature gradient discrete value of the temperature measurement point belonging to the metal casting forming process.

[0038] It is the reference content of the nth key material in the molten metal in the metal casting process, indicating the reference value for analyzing the content of the nth key material in the molten metal in the metal casting process.

[0039] e is a natural constant, n is the number of each key material, , m is the total number of key materials.

[0040] in, The residual stress risk assessment value of the metal casting process is shown in Figure 1. The pouring speed of the molten metal is an important parameter in the metal casting process, which directly affects the temperature gradient of the casting. A faster pouring speed may lead to local overheating and abnormally large temperature gradient discrete values, that is, temperature gradient discrete values ​​that deviate from the reference temperature gradient discrete value. A slower pouring speed may cause the molten metal to stay in the mold for too long, resulting in uneven cooling, which makes the temperature gradient discrete value deviate from the reference temperature gradient discrete value. At the same time, the content of key materials also has a significant impact on the pouring speed and temperature gradient. The content of key materials can change the properties of the molten metal such as fluidity, melting point and heat capacity, thereby affecting the distribution of the pouring speed and temperature gradient. For example, the content of key materials deviates greatly from the reference content of key materials, which makes the molten metal fluidity abnormal, resulting in a large deviation of the average pouring speed of the molten metal from the reference average pouring speed, further aggravating the abnormality of the temperature gradient discrete value. Therefore, in the residual stress risk assessment of the metal casting process, it is necessary to comprehensively consider the interaction between parameters such as the molten metal pouring flow rate, the standard deviation of the temperature gradient and the alloy component content, so as to optimize the casting process, reduce the residual stress level, and improve the mechanical properties and service life of the casting.

[0041] Furthermore, the big data analyzes the residual stress risk assessment value of the metal casting process, and the specific analysis process is:

[0042] The pouring volume of the molten metal in each pouring monitoring sub-cycle of the metal casting molding process is extracted from the simulation process parameters of the metal casting molding process, and the ratio processing is performed with the duration corresponding to the pouring monitoring sub-cycle to obtain the pouring speed of the molten metal in each pouring monitoring sub-cycle of the metal casting molding process, and the average pouring speed of the molten metal in the metal casting molding process is obtained by average processing; the corresponding duration of each of the above-mentioned pouring monitoring sub-cycles is an arithmetic progression, such as 3 seconds, 5 seconds, 7 seconds, 10 seconds and 12 seconds, etc., which is specifically formulated by the casting process engineer taking into account the fluidity of the molten metal, the cooling speed of the mold, the size and shape of the casting, the production efficiency and the requirements of quality control. The flow speed of the molten metal may change with the passage of pouring time. By setting the duration of the pouring monitoring sub-cycle to an arithmetic progression, the change of the flow speed of the molten metal can be captured more carefully; the pouring volume of the molten metal in each pouring monitoring sub-cycle of the above-mentioned metal casting molding process is simulated by the metal casting molding process simulation analysis platform, and can be obtained by monitoring the volume of the molten metal flowing through the gate by a flow meter in the actual manufacturing process.

[0043] The contents of key materials of the molten metal belonging to the metal casting molding process are extracted from the simulation process parameters of the metal casting molding process. At the same time, the temperature values ​​of each temperature measurement point belonging to the metal casting molding process at the end time point of the pouring monitoring cycle are extracted from the simulation process parameters of the metal casting molding process. The temperature values ​​of adjacent temperature measurement points at the end time point of the pouring monitoring cycle are subjected to difference processing, and the difference processing results are subjected to standard deviation processing, and the standard deviation processing results are marked as the temperature gradient discrete values ​​of the temperature measurement points belonging to the metal casting molding process; the above-mentioned temperature measurement points are marked by the metal casting molding process administrator on the machine tool mold belonging to the metal casting, and thus synchronized to the metal casting molding process simulation analysis platform. It should be explained that the distance between each temperature measurement point in the numerical direction is equal, such as Figure 3 As shown in the schematic diagram of the machine tool mold, the vertical distance 4 between the temperature measurement point 1 and the temperature measurement point 2 is equal to the vertical distance 5 between the temperature measurement point 2 and the temperature measurement point 3. Therefore, the adjacent measurement point of the temperature measurement point 1 is the temperature measurement point 2, and the adjacent measurement point of the temperature measurement point 2 is the temperature measurement point 3. It should be noted that in order to ensure that the result of the difference processing of the temperature value is low in repeatability, the adjacent temperature measurement points in this embodiment refer to a certain temperature measurement point and the adjacent temperature measurement points with a lower vertical position; the temperature values ​​of each temperature measurement point belonging to the above-mentioned metal casting molding process at the end time of the pouring monitoring cycle are simulated by the metal casting molding process simulation analysis platform, and can be obtained by monitoring by the temperature sensor in the actual manufacturing process; the above-mentioned pouring monitoring cycle refers to the cycle of pouring molten metal into the machine tool mold, and its specific duration varies according to the simulation situation; the content of each key material in the molten metal belonging to the above-mentioned metal casting molding process can be obtained by spectral analysis method in actual manufacturing, and the content of each element in the molten metal is determined by measuring the intensity or wavelength of these lights using the properties of the material emitting or absorbing light of a specific wavelength.

[0044] The reference content of each key material of the molten metal belonging to the metal casting molding process is extracted from the basic parameters of the component to be cast, and the residual stress risk assessment value of the metal casting molding process is analyzed based on big data; the reference content of each key material of the molten metal belonging to the above-mentioned metal casting molding process refers to the reference content formulated by the casting process engineer according to the design requirements, use environment and process conditions of the casting.

[0045] The process optimization module is used to compare the residual stress risk assessment value of the metal casting molding process with the residual stress risk assessment threshold. If the residual stress risk assessment value of the metal casting molding process is less than or equal to the residual stress risk assessment threshold, the casting feedback module is executed. If the residual stress risk assessment value of the metal casting molding process is greater than the residual stress risk assessment threshold, the process optimization set of the metal casting molding process is matched and executed, thereby evaluating the process optimization index of the metal casting molding process.

[0046] The above-mentioned residual stress risk assessment threshold represents the minimum value of a reasonable range of residual stress risk assessment values ​​for analyzing the metal casting molding process, which is extracted from the casting database. If the residual stress risk assessment value of the metal casting molding process is greater than the residual stress risk assessment threshold, it indicates that under the simulation process parameters of the current metal casting molding process, the result of the metal casting molding process exhibits a higher residual stress level, and measures need to be taken to improve it.

[0047] In a specific embodiment, the present invention executes a process optimization set for a metal casting molding process, and after the execution, conducts an in-depth analysis of the parameters of the quenching stage in the metal casting molding process. This can accurately evaluate the effectiveness of the process optimization set in making subtle adjustments to the metal casting molding process. At the same time, the performance of the quenching stage can map the quality and effectiveness of the processes in each stage before the quenching stage, thereby becoming an important window for measuring the overall process level. This method also effectively reduces the complexity of data processing work and improves the efficiency of parameter analysis of the metal casting molding process.

[0048] Specifically, the process optimization set of matching and executing the metal casting forming process is specifically matched as follows:

[0049] The residual stress risk assessment value of the metal casting molding process is ratioed with the residual stress risk assessment threshold to obtain a residual stress risk assessment proportional coefficient of the metal casting molding process;

[0050] The residual stress risk assessment proportional coefficient of the metal casting molding process is matched with the process optimization set corresponding to each residual stress risk assessment proportional coefficient interval stored in the casting database, thereby obtaining and simulating the process optimization set of the metal casting molding process, and updating the residual stress risk assessment value of the metal casting molding process, which is marked as the updated residual stress risk assessment value of the metal casting molding process; the process optimization set corresponding to each residual stress risk assessment proportional coefficient interval stored in the above casting database, the specific matching rules and matching values ​​are formulated by quality control experts according to the performance requirements of residual stress. In an example embodiment, the process optimization set of the above metal casting molding process has a specific matching process as follows: assuming that the residual stress risk assessment proportional coefficient of the metal casting molding process is 200%, which belongs to the residual stress risk assessment proportional coefficient interval [180%, 210%] stored in the casting database, then the process optimization set corresponding to the residual stress risk assessment proportional coefficient interval [180%, 210%] includes: the silicon content of the molten metal is increased to 8%, the magnesium content is increased to 0.5%, and the copper content is adjusted to 4.2%. To enhance the strength and hardness of the alloy, the iron content is reduced to 0.7% to reduce the adverse effects of impurities on the performance of the casting, the pouring temperature is increased to 720 degrees Celsius to improve the fluidity and filling of the molten metal, and the pouring speed is accelerated to 15 kg of molten metal flowing through the gate per second to improve production efficiency, the machine tool mold temperature is greatly reduced to 200 degrees Celsius to accelerate the cooling speed and reduce thermal stress, the casting pressure is greatly increased to 150 MPa to significantly improve the density and mechanical properties of the casting, the quenching water temperature is adjusted to -35 degrees Celsius to enhance the cooling effect, the quenching time is shortened to 3 seconds to speed up the production cycle, and the quenching pressure is increased to 0.7 MPa to enhance the pressure transfer during the cooling process, so that the process optimization set of the metal casting molding process also includes the above conditions; the above-mentioned updated residual stress risk assessment value of the metal casting molding process refers to analyzing and simulating the parameters in the metal casting molding process after executing the process optimization set of the metal casting molding process according to the analysis process of the residual stress risk assessment value of the metal casting molding process, and marking the analysis results as the updated residual stress risk assessment value of the metal casting molding process.

[0051] Furthermore, the process optimization index of the metal casting molding process is evaluated, and the specific evaluation process is as follows:

[0052] Based on the process optimization set of simulating the execution of the metal casting forming process, the quenching parameters of the metal casting forming process in the quenching monitoring cycle are collected, thereby extracting the flow rate of the quenching water belonging to the metal casting forming process in each quenching monitoring sub-cycle, and the standard deviation processing result is marked as the discrete value of the flow rate of the quenching water belonging to the metal casting forming process; the above-mentioned quenching monitoring sub-cycle represents the sub-cycle for monitoring the quenching stage of the metal casting forming process, and the duration of each quenching monitoring sub-cycle is equal, and the specific duration is determined by material science experts based on material properties, organizational structure, and mechanical properties; the flow rate of the quenching water belonging to the above-mentioned metal casting forming process in each quenching monitoring sub-cycle is simulated by the metal casting forming process simulation analysis platform, and in the actual manufacturing process, it can be obtained by monitoring the volume of the quenching water flowing through the quenching water inlet pipe through the flowmeter.

[0053] The average temperature of the quenching water belonging to the metal casting molding process during the quenching monitoring period is extracted from the quenching parameters of the metal casting molding process during the quenching monitoring period, and is simulated through the metal casting molding process simulation analysis platform. In the actual manufacturing process, it can be detected and analyzed by temperature sensors installed in the quenching water pipe and the cooling water tank.

[0054] At the same time, combined with the updated residual stress risk assessment value of the metal casting molding process, an evaluation method for the process optimization index of the metal casting molding process is obtained. In this embodiment, the process optimization index of the metal casting molding process is obtained by comprehensive analysis of the updated residual stress risk assessment value of the metal casting molding process, the flow discrete value of the quenching water belonging to the metal casting molding process, and the average temperature of the quenching water belonging to the metal casting molding process during the quenching monitoring period. It is a value used to evaluate the process optimization effect of the metal casting molding process. The specific evaluation method is as follows:

[0055] ;

[0056] It is an updated residual stress risk assessment value for the metal casting process, which is obtained through a comprehensive analysis of the average pouring speed of the molten metal in the metal casting process, the discrete values ​​of the temperature gradient of the temperature measurement points in the metal casting process, and the content of each key material in the molten metal in the metal casting process. It is a numerical value used to analyze the residual stress risk degree of the metal casting process.

[0057] It is the discrete value of the flow rate of the quenching water in the metal casting process, which refers to the numerical value of the discrete degree of the flow data of the quenching water in each quenching monitoring sub-cycle during the metal casting process.

[0058] It is the average temperature of the quenching water in the metal casting process during the quenching monitoring cycle, which refers to the average value of the temperature data measured by the quenching water in the quenching monitoring cycle during the metal casting process.

[0059] It is the reference flow discrete value preset in the casting database, which represents the reference value for analyzing the flow discrete value of the quenching water in the metal casting process.

[0060] It is the reference average temperature preset in the casting database, which represents the reference value for analyzing the average temperature of the quenching water in the quenching monitoring cycle of the metal casting molding process.

[0061] e is a natural constant, It is the weight factor corresponding to the updated residual stress risk assessment value preset in the casting database, which represents the proportion of the updated residual stress risk assessment value to the process optimization index. When used, the weight factor corresponding to the updated residual stress risk assessment value can be directly obtained from the casting database, and the corresponding relationship can be a preset mapping relationship. For example, the average pouring speed of the molten metal belonging to the metal casting molding process, the discrete value of the temperature gradient of the temperature measurement point belonging to the metal casting molding process, and the content of each key material of the molten metal belonging to the metal casting molding process form a mapping set with the weight factor corresponding to the updated residual stress risk assessment value preset in the casting database. The real-time average pouring speed of the molten metal belonging to the metal casting molding process, the discrete value of the temperature gradient of the temperature measurement point belonging to the metal casting molding process, and the content of each key material of the molten metal belonging to the metal casting molding process are input into the mapping set to obtain the weight factor corresponding to the updated residual stress risk assessment value. The mapping relationship can be one-to-one or many-to-one. In this example, its value range is [0, 1].

[0062] in, It is the process optimization index of the metal casting molding process. When the average temperature of the quenching water deviates greatly from the reference average temperature, for example, when the average temperature of the quenching water is high, the casting takes a longer time to release heat, which may cause pressure changes in the cooling system, thereby affecting the flow rate of the quenching water. In order to maintain the cooling rate of the casting, the flow rate of the quenching water needs to be increased to compensate for the higher temperature. The increase in the flow rate of the quenching water may reduce the stability of the system and cause the flow rate fluctuation to increase. The discrete value of the flow rate of the quenching water reflects the instability of the water flow rate during the quenching process. When the flow discrete value deviates greatly from the reference flow discrete value, it indicates that the flow rate of the quenching water has large fluctuations at different time points. This fluctuation may cause the casting to be subjected to uneven thermal stress during the cooling process, thereby increasing the risk of residual stress. At the same time, combined with the residual stress risk assessment value of the metal casting molding process, the optimization degree of the process optimization set of the metal casting molding process can be comprehensively evaluated. By combining residual stress risk assessment and real-time monitoring and adjustment and other measures, the risks of thermal stress and residual stress in the manufacturing of castings can be significantly reduced, and the quality and performance of castings can be improved.

[0063] The process adjustment module is used to compare the process optimization index of the metal casting molding process with the process optimization threshold. If the process optimization index of the metal casting molding process is greater than the process optimization threshold, the simulation process parameters of the metal casting molding process are updated and the casting feedback module is executed. If the process optimization index of the metal casting molding process is less than or equal to the process optimization threshold, the process optimization set of the metal casting molding process is adjusted to determine the process adjustment index of the metal casting molding process, thereby adjusting and feedbacking the intelligent control of residual stress in the metal casting molding process.

[0064] The above-mentioned process optimization threshold represents the minimum value of a reasonable range of a process optimization index for analyzing a metal casting molding process, which is extracted from a casting database; if the process optimization index of the above-mentioned metal casting molding process is less than or equal to the process optimization threshold, it indicates that under the condition that the parameters in the process optimization set of the metal casting molding process simulate the metal casting molding process, the result of the metal casting molding process exhibits a higher residual stress level, indicating that slight adjustments to the simulated process parameters of the metal casting molding process cannot meet the performance requirements of the casting, and therefore measures need to be taken to improve it.

[0065] In a specific embodiment, given that the process optimization set of the metal casting molding process can no longer meet the needs of the current metal casting molding process, the process optimization set of the metal casting molding process is comprehensively adjusted through the parameter adjustment set of the metal casting molding process. Therefore, the present invention executes the parameter adjustment set of the metal casting molding process and analyzes the parameters in the overall metal casting molding process after the execution is completed. It can timely discover and solve potential quality problems, thereby intelligently selecting the optimal parameters of the metal casting molding process to ensure that the products of metal casting molding always meet the quality requirements.

[0066] Specifically, the intelligent control of residual stress in the metal casting process is adjusted and fed back, and the specific adjustment and feedback process is:

[0067] The process adjustment index of the metal casting molding process is compared with the process adjustment threshold. If the process adjustment index of the metal casting molding process is less than or equal to the process adjustment threshold, the process adjustment threshold is subjected to difference processing with the process adjustment index of the metal casting molding process to obtain the process adjustment difference of the metal casting molding process, which is matched with the parameter adjustment set corresponding to each process adjustment difference interval stored in the casting database to obtain the parameter adjustment set of the metal casting molding process, thereby adjusting the process optimization set of the metal casting molding process until the process adjustment index of the metal casting molding process is greater than the process adjustment threshold; the specific matching rules and matching values ​​of the parameter adjustment set corresponding to each process adjustment difference interval stored in the casting database are determined by the quality control experts according to the residual The performance requirements of stress and the simulated production efficiency of the process optimization set of the metal casting molding process are formulated. In an exemplary embodiment, the parameter adjustment set of the above-mentioned metal casting molding process, the specific matching process is: assuming that the process adjustment difference of the metal casting molding process is 250%, within the process adjustment difference interval [240%, 280%] stored in the casting database, the parameter adjustment set corresponding to the process adjustment difference interval [240%, 280%] includes: the silicon content of the molten metal is increased to 8%, the magnesium content is increased to 0.5%, the copper content is adjusted to 4.2% to enhance the strength and hardness of the alloy, and the iron content is reduced to 0.7% to reduce the adverse effects of impurities on the performance of the casting, and the pouring temperature is increased to 720 degrees Celsius to improve the fluidity and filling of the molten metal. The pouring speed is increased to 15 kg of molten metal flowing through the gate per second to improve production efficiency, the machine tool mold temperature is greatly reduced to 200 degrees Celsius to accelerate the cooling speed and reduce thermal stress, the casting pressure is greatly increased to 150 MPa to significantly improve the density and mechanical properties of the casting, the quenching water temperature is adjusted to -35 degrees Celsius to enhance the cooling effect, the quenching time is shortened to 3 seconds to speed up the production cycle, and the quenching pressure is increased to 0.7 MPa to enhance the pressure transfer during the cooling process. The process optimization set of the metal casting molding process includes the above parameters; the process optimization set of the metal casting molding process is adjusted to the process adjustment index of the metal casting molding process is greater than the process adjustment threshold. If the parameter adjustment set of the metal casting molding process is executed, If the process adjustment index of the metal casting molding process is still less than or equal to the process adjustment threshold, the process adjustment index of the metal casting molding process after executing the parameter adjustment set of the metal casting molding process is determined according to the method for determining the process adjustment index of the metal casting molding process, and continue to perform comparison and matching operations with the process adjustment threshold until the process adjustment index of the metal casting molding process is greater than the process adjustment threshold. It should be explained that the parameter adjustment set of the metal casting molding process has been matched fewer times, such as three or four times, in the historical adjustment process. The parameter adjustment set of the metal casting molding process is more scientific. Therefore, until the process adjustment index of the metal casting molding process is greater than the process adjustment threshold, it is only necessary to match the parameter adjustment set of the metal casting molding process once or less times.

[0068] If the process adjustment index of the metal casting molding process is greater than the process adjustment threshold, the adjustment parameters for adjusting the process optimization set of the metal casting molding process are collected, and the process optimization set of the metal casting molding process is adjusted based on the process optimization set of the metal casting molding process and the adjustment parameters, thereby updating the simulation process parameters of the metal casting molding process, generating a pre-production parameter preparation set of the metal casting molding process, transmitting the updated simulation process parameters of the metal casting molding process to the pre-production parameter preparation set of the metal casting molding process, and feeding back the pre-production parameter preparation set of the metal casting molding process in the form of a log, thereby completing the adjustment feedback of the intelligent control of the residual stress of the metal casting molding process; in an exemplary embodiment, the pre-production parameter preparation set of the metal casting molding process includes: The silicon content of the molten metal was increased to 8%, the magnesium content was increased to 0.5%, and the copper content was adjusted to 4.2% to enhance the strength and hardness of the alloy. At the same time, the iron content was reduced to 0.7% to reduce the adverse effects of impurities on the performance of the casting. The pouring temperature was increased to 720 degrees Celsius to improve the fluidity and filling of the molten metal. The pouring speed was increased to 15 kilograms of molten metal flowing through the gate per second to improve production efficiency. The machine tool mold temperature was greatly reduced to 200 degrees Celsius to speed up the cooling speed and reduce thermal stress. The casting pressure was greatly increased to 150 MPa to significantly improve the density and mechanical properties of the casting. The chilling water temperature was adjusted to -35 degrees Celsius to enhance the cooling effect. The chilling time was shortened to 3 seconds to speed up the production cycle. At the same time, the chilling pressure was increased to 0.7 MPa to enhance the pressure transfer during the cooling process.

[0069] Furthermore, the process of determining the process adjustment index of the metal casting molding process is specifically determined as follows:

[0070] Based on the adjustment of the process optimization set of the metal casting molding process, the total duration of the metal casting molding process is collected and recorded as the process optimization adjustment cycle of the metal casting molding process; the total duration of the above-mentioned metal casting molding process is simulated by the metal casting molding process simulation analysis platform, and can be obtained through the production record system of the machine tool mold equipment in the actual manufacturing process.

[0071] At the same time, the average pouring speed of the molten metal belonging to the metal casting molding process during the process optimization and adjustment period and the discrete values ​​of the flow rate of the quenching water belonging to the metal casting molding process during the process optimization and adjustment period are collected; the method for obtaining the average pouring speed of the molten metal belonging to the above-mentioned metal casting molding process during the process optimization and adjustment period is consistent with the method for obtaining the average pouring speed of the molten metal belonging to the metal casting molding process in the residual stress risk assessment value of the metal casting molding process; the method for obtaining the discrete values ​​of the flow rate of the quenching water belonging to the above-mentioned metal casting molding process during the process optimization and adjustment period is consistent with the method for obtaining the discrete values ​​of the flow rate of the quenching water belonging to the metal casting molding process in the process optimization index of the metal casting molding process.

[0072] Thus, a method for determining the process adjustment index of the metal casting molding process is obtained. In this embodiment, the process adjustment index of the metal casting molding process is obtained by comprehensively analyzing the average pouring speed, flow rate discrete value and the total duration of the metal casting molding process of the metal liquid in the process optimization adjustment cycle of the metal casting molding process, and is used to determine the value of the process adjustment effect of the metal casting molding process. The specific determination process is as follows:

[0073] ;

[0074] It is the average pouring speed of the molten metal in the metal casting process during the process optimization and adjustment cycle, and refers to the average volume of the molten metal flowing through the gate per unit time during the process optimization and adjustment cycle.

[0075] It is the discrete value of the flow rate of the quenching water in the metal casting molding process during the process optimization and adjustment cycle, which refers to the numerical value of the discrete degree of the flow data monitored by the quenching water in the process optimization and adjustment cycle during the metal casting molding process.

[0076] It is the total duration of the metal casting process, which refers to the total duration of the casting stage of the metal casting process, specifically including the casting stage and the cooling stage.

[0077] e is a natural constant, It is the reference average pouring speed preset in the casting database, which represents the reference value of the average pouring speed of the molten metal in the metal casting process.

[0078] It is the reference flow discrete value preset in the casting database, which represents the reference value for analyzing the flow discrete value of the quenching water in the metal casting process.

[0079] It is the reference total time preset in the casting database, which represents the reference value of the total time for analyzing the metal casting forming process.

[0080] in, It is the process adjustment index of the metal casting process. When the average pouring speed deviates from the reference average pouring speed, it directly affects the filling speed, flow pattern and temperature uniformity of the molten metal in the machine tool mold. The non-uniformity of the molten metal temperature requires the cooling system of the metal casting process to make more precise adjustments to maintain the cooling rate of each part of the casting consistent, which leads to an increase in the discrete value of the quenching water flow. This uneven cooling will prolong the overall solidification time of the casting, because it is necessary to wait for the slowest cooling part to completely solidify before the next operation can be carried out. The increase in the discrete value of the quenching water flow usually causes the total duration of the metal casting process to deviate greatly from the reference total duration. Therefore, it is determined that the metal casting process is When optimizing and adjusting the process, it is necessary to analyze the effects of the above parameters and whether the influence between the above parameters has been effectively improved, as well as whether the metal casting molding process has reached the threshold requirements set by the process adjustment. When the above parameters deviate from the reference value by a small amount and the relationship between them can meet the process adjustment threshold, it indicates that the process optimization adjustment is in line with the technical requirements. The above parameters are extracted from the entire metal casting molding process from the pouring of molten metal to the complete solidification of the casting, which together constitute a comprehensive and in-depth understanding of the metal casting molding process. This can accurately determine the adjustment effect of the process optimization set for the metal casting molding process, thereby laying a scientific data foundation for the subsequent automated matching simulation process parameters.

[0081] In this exemplary embodiment, the process adjustment index of the metal casting process and its corresponding parameter variation table are shown in Table 1:

[0082] Table 1 Changes of process adjustment index and corresponding parameters in metal casting process

[0083] Average pouring speed / liter / minute Flow discrete value / percentage Total time / minutes Process adjustment index / percentage 20 32 560 24 23 40 600 23 30 41.5 615 20

[0084] In this example embodiment, the reference average pouring speed is set to 20 liters / minute, the reference flow discrete value is set to 35%, and the reference total duration is set to 575 minutes. It can be seen from Table 1 that when the average pouring speed, the flow discrete value and the total duration deviate from the corresponding reference values ​​by a small amount (such as the second row of data in Table 1), the process adjustment index is large, that is, the process of the metal casting molding process is further adjusted and optimized to a higher level; when the average pouring speed, the flow discrete value and the total duration deviate from the corresponding reference values ​​by a large amount (such as the fourth row of data in Table 1), the process adjustment index is small, that is, the level of adjustment and optimization of the process of the metal casting molding process is low.

[0085] The casting feedback module is used to collect simulation process parameters of the metal casting molding process and provide feedback on the simulation process parameters of the metal casting molding process.

[0086] Specifically, if the residual stress risk assessment value of the metal casting molding process is less than or equal to the residual stress risk assessment threshold, a parameter preparation setting set of the metal casting molding process is generated, the simulation process parameters of the metal casting molding process are transmitted to the parameter preparation setting set of the metal casting molding process, and the parameter preparation setting set of the metal casting molding process is fed back in the form of a log, thereby completing the feedback of the simulation process parameters of the metal casting molding process; if the residual stress risk assessment value of the metal casting molding process is less than or equal to the residual stress risk assessment threshold, it indicates that under the simulation process parameters of the current metal casting molding process, the metal casting molding process The result is a lower residual stress level, so the simulated process parameters of the metal casting molding process can be applied to the actual metal casting molding process; in an exemplary embodiment, the parameter preparation set of the above-mentioned metal casting molding process includes: the silicon content of the molten metal is 7%, the magnesium content of the molten metal is 0.4%, the copper content of the molten metal is 3.9%, the iron content of the molten metal is 0.9%, the pouring temperature is 700 degrees Celsius, the pouring speed is 10 kilograms of molten metal flowing through the gate per second, the machine tool mold temperature is 250 degrees Celsius, the casting pressure is 100 MPa, the quenching water temperature is -30 degrees Celsius, the quenching time is 5 seconds, and the quenching pressure is 0.5 MPa.

[0087] Specifically, if the process optimization index of the metal casting molding process is greater than the process optimization threshold, a parameter preparation configuration set of the metal casting molding process is generated, and the simulation process parameters of the metal casting molding process are updated based on the process optimization set of the metal casting molding process, and the updated simulation process parameters of the metal casting molding process are transmitted to the parameter preparation configuration set of the metal casting molding process, and the parameter preparation configuration set of the metal casting molding process is fed back in the form of a log, thereby completing the feedback of the simulation process parameters of the metal casting molding process; if the process optimization index of the metal casting molding process is greater than the process optimization threshold, it indicates that under the condition that the parameters in the process optimization set of the metal casting molding process simulate the metal casting molding process, the result of the metal casting molding process exhibits a lower residual stress level, and therefore the parameters in the process optimization set of the metal casting molding process can be The number is applied to the actual metal casting molding process; in an exemplary embodiment, the parameter pre-configuration set of the above metal casting molding process includes: the silicon content of the molten metal is maintained at 0.4%, the magnesium content is fine-tuned to 0.39%, the copper content is maintained at 3.85% to optimize the mechanical properties of the alloy, the iron content is controlled at 0.85% to reduce the influence of impurities, the pouring temperature is set to 695 degrees Celsius to fine-tune the fluidity of the molten metal, the pouring speed is maintained at 10 kilograms of molten metal flowing through the gate per second, the machine tool mold temperature is maintained at 245 degrees Celsius to ensure good heat transfer and reduce thermal stress, the casting pressure is slightly increased to 105 MPa to improve the density and mechanical strength of the casting, the chilling water temperature is slightly adjusted to -28 degrees Celsius to optimize the cooling effect, the chilling time is slightly shortened to 4.5 seconds to speed up the production cycle, and the chilling pressure is maintained at 0.5 MPa to maintain a stable cooling pressure environment.

[0088] It should be explained that the pre-production parameter preparation set of the metal casting molding process, the parameter preparation setting set of the metal casting molding process and the parameter preparation configuration set of the metal casting molding process are just empty sets when generated.

[0089] In a specific embodiment, the present invention provides a residual stress control system and method based on metal casting molding, collects simulation process parameters of the metal casting molding process and basic parameters of the components to be cast, analyzes the residual stress risk assessment value of the metal casting molding process through big data, and obtains the process optimization set of the metal casting molding process, which is helpful to identify potential casting problems from the root and provide strong data support for subsequent casting optimization work. By evaluating the process optimization index of the metal casting molding process after executing the process optimization set of the metal casting molding process, the actual effect brought by the process optimization is quantified, providing a basis for subsequent adjustments and improvements. By adjusting the process optimization set of the metal casting molding process, the process adjustment index of the metal casting molding process is determined, and finally the intelligent control of the residual stress of the metal casting molding process is adjusted and fed back, so that the metal casting molding process meets the actual casting requirements. Through continuous iteration and adjustment, the refined and intelligent control of the metal casting molding process is realized, and the production efficiency and product quality of the metal casting molding process are improved.

[0090] Reference Figure 2 As shown, the second aspect of the present invention provides a method for the residual stress control system based on metal casting molding, comprising: S1. Through the simulation process of metal casting molding, the simulation process parameters of the metal casting molding process and the basic parameters of the components to be cast are collected, and the residual stress risk assessment value of the metal casting molding process is analyzed by big data; S2. The residual stress risk assessment value of the metal casting molding process is compared with the residual stress risk assessment threshold. If the residual stress risk assessment value of the metal casting molding process is less than or equal to the residual stress risk assessment threshold, S4 is executed; if the residual stress risk assessment value of the metal casting molding process is greater than the residual stress risk assessment threshold, the metal casting molding process is matched and executed. The process optimization set of the metal casting molding process is used to evaluate the process optimization index of the metal casting molding process; S3. The process optimization index of the metal casting molding process is compared with the process optimization threshold. If the process optimization index of the metal casting molding process is greater than the process optimization threshold, the simulation process parameters of the metal casting molding process are updated and S4 is executed. If the process optimization index of the metal casting molding process is less than or equal to the process optimization threshold, the process optimization set of the metal casting molding process is adjusted to determine the process adjustment index of the metal casting molding process, thereby adjusting and feeding back the intelligent control of the residual stress of the metal casting molding process; S4. The simulation process parameters of the metal casting molding process are collected and the simulation process parameters of the metal casting molding process are fed back.

[0091] 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 present invention, they should all fall within the protection scope of the present invention.

Claims

1. A residual stress control system based on metal casting, characterized in that: include: The risk assessment module is used to collect the simulation process parameters of the metal casting process and the basic parameters of the components to be cast through the simulation process of metal casting, and analyze the residual stress risk assessment value of the metal casting process based on big data; A process optimization module is used to compare the residual stress risk assessment value of the metal casting molding process with the residual stress risk assessment threshold. If the residual stress risk assessment value of the metal casting molding process is less than or equal to the residual stress risk assessment threshold, the casting feedback module is executed. If the residual stress risk assessment value of the metal casting molding process is greater than the residual stress risk assessment threshold, the process optimization set of the metal casting molding process is matched and executed, thereby evaluating the process optimization index of the metal casting molding process; A process adjustment module is used to compare the process optimization index of the metal casting molding process with the process optimization threshold. If the process optimization index of the metal casting molding process is greater than the process optimization threshold, the simulation process parameters of the metal casting molding process are updated and the casting feedback module is executed. If the process optimization index of the metal casting molding process is less than or equal to the process optimization threshold, the process optimization set of the metal casting molding process is adjusted to determine the process adjustment index of the metal casting molding process, thereby adjusting and feeding back the intelligent control of the residual stress of the metal casting molding process; A casting feedback module is used to collect simulation process parameters of the metal casting molding process and provide feedback on the simulation process parameters of the metal casting molding process; The big data analysis of the residual stress risk assessment value of the metal casting process is as follows: Extracting the pouring volume of the molten metal in each pouring monitoring sub-period of the metal casting process from the simulation process parameters of the metal casting process, performing ratio processing with the duration corresponding to the pouring monitoring sub-period to obtain the pouring speed of the molten metal in each pouring monitoring sub-period of the metal casting process, and performing mean processing to obtain the average pouring speed of the molten metal in the metal casting process; Extracting the contents of key materials of the molten metal belonging to the metal casting molding process from the simulation process parameters of the metal casting molding process, and at the same time extracting the temperature values ​​of each temperature measurement point belonging to the metal casting molding process at the end time point of the pouring monitoring cycle from the simulation process parameters of the metal casting molding process, performing difference processing on the temperature values ​​of adjacent temperature measurement points at the end time point of the pouring monitoring cycle, performing standard deviation processing on the difference processing results, and marking the standard deviation processing results as temperature gradient discrete values ​​of the temperature measurement points belonging to the metal casting molding process; Extract the reference content of each key material in the molten metal of the metal casting process from the basic parameters of the component to be cast, and use this big data to analyze the residual stress risk assessment value of the metal casting process; The residual stress risk assessment value of the metal casting process is specifically analyzed as follows: ； in, is the residual stress risk assessment value of the metal casting process, It is the average pouring speed of the molten metal in the metal casting process. is the discrete value of the temperature gradient at the temperature measurement point in the metal casting process. It is the nth key material content of the molten metal in the metal casting process. is the reference average pouring speed preset in the casting database, is the reference temperature gradient discrete value preset in the casting database, is the reference content of the nth key material in the metal liquid in the metal casting process, e is a natural constant, n is the number of each key material, , m is the total number of key materials; The process optimization set of matching and executing the metal casting forming process is specifically matched as follows: The residual stress risk assessment value of the metal casting molding process is ratioed with the residual stress risk assessment threshold to obtain a residual stress risk assessment proportional coefficient of the metal casting molding process; Matching the residual stress risk assessment proportional coefficient of the metal casting molding process with the process optimization set corresponding to each residual stress risk assessment proportional coefficient interval stored in the casting database, thereby obtaining and simulating the process optimization set of the metal casting molding process, and updating the residual stress risk assessment value of the metal casting molding process, which is marked as the updated residual stress risk assessment value of the metal casting molding process; The process optimization index for evaluating the metal casting process is specifically evaluated as follows: Based on the process optimization set of simulating the execution of the metal casting forming process, the chilling parameters of the metal casting forming process in the chilling monitoring cycle are collected, thereby extracting the flow rate of the chilling water belonging to the metal casting forming process in each chilling monitoring sub-cycle, and the standard deviation processing result is marked as the discrete value of the flow rate of the chilling water belonging to the metal casting forming process; The average temperature of the quenching water in the metal casting process during the quenching monitoring period is extracted from the quenching parameters of the metal casting process during the quenching monitoring period, and the updated residual stress risk assessment value of the metal casting process is combined to obtain an assessment method for the process optimization index of the metal casting process; The specific determination process of determining the process adjustment index of the metal casting molding process is as follows: Based on adjusting the process optimization set of the metal casting molding process, the total duration of the metal casting molding process is collected and recorded as the process optimization adjustment cycle of the metal casting molding process; At the same time, the average pouring speed of the molten metal in the process of metal casting molding and the discrete value of the flow rate of the quenching water in the process of metal casting molding are collected, thereby obtaining a determination method for the process adjustment index of the metal casting molding process; The process optimization index of the metal casting molding process is obtained by comprehensive analysis of the updated residual stress risk assessment value of the metal casting molding process, the flow discrete value of the quenching water belonging to the metal casting molding process, and the average temperature of the quenching water belonging to the metal casting molding process during the quenching monitoring period. It is used to evaluate the process optimization effect of the metal casting molding process. The specific evaluation method is as follows: ； in, It is the process optimization index of metal casting process. Updated residual stress risk assessment values ​​for metal casting processes, is the discrete value of the flow rate of quenching water in the metal casting process, It is the average temperature of the quenching water in the metal casting process during the quenching monitoring period. It is the reference flow discrete value preset in the casting database. is the reference average temperature preset in the casting database, e is a natural constant, The weight factor corresponding to the updated residual stress risk assessment value preset in the casting database; The process adjustment index of the metal casting molding process is obtained by comprehensively analyzing the average pouring speed, flow rate discrete value and the total duration of the metal casting molding process of the metal liquid in the process optimization adjustment cycle of the metal casting molding process, and is used to determine the value of the process adjustment effect of the metal casting molding process. The specific determination process is as follows: ； in, It is the process adjustment index of metal casting process. It is the average pouring speed of the molten metal in the metal casting process during the process optimization and adjustment period. It is the discrete value of the flow rate of the quenching water in the metal casting process during the process optimization and adjustment period. is the total duration of the metal casting process, e is a natural constant, is the reference average pouring speed preset in the casting database, It is the reference flow discrete value preset in the casting database. It is the reference total duration preset in the casting database.

2. The residual stress control system based on metal casting according to claim 1, characterized in that: If the residual stress risk assessment value of the metal casting molding process is less than or equal to the residual stress risk assessment threshold, a parameter preparation setting set of the metal casting molding process is generated, the simulation process parameters of the metal casting molding process are transmitted to the parameter preparation setting set of the metal casting molding process, and the parameter preparation setting set of the metal casting molding process is fed back in the form of a log, thereby completing the feedback of the simulation process parameters of the metal casting molding process.

3. The residual stress control system based on metal casting according to claim 1 is characterized in that: If the process optimization index of the metal casting molding process is greater than the process optimization threshold, a parameter preparation configuration set of the metal casting molding process is generated, and the simulation process parameters of the metal casting molding process are updated based on the process optimization set of the metal casting molding process, and the updated simulation process parameters of the metal casting molding process are transmitted to the parameter preparation configuration set of the metal casting molding process, and the parameter preparation configuration set of the metal casting molding process is fed back in the form of a log, thereby completing the feedback of the simulation process parameters of the metal casting molding process.

4. The residual stress control system based on metal casting according to claim 1 is characterized in that: The intelligent control of residual stress in the metal casting process is adjusted and fed back, and the specific adjustment and feedback process is as follows: The process adjustment index of the metal casting molding process is compared with the process adjustment threshold. If the process adjustment index of the metal casting molding process is less than or equal to the process adjustment threshold, the process adjustment threshold is subjected to difference processing with the process adjustment index of the metal casting molding process to obtain the process adjustment difference of the metal casting molding process, and the difference is matched with the parameter adjustment set corresponding to each process adjustment difference interval stored in the casting database to obtain the parameter adjustment set of the metal casting molding process, thereby adjusting the process optimization set of the metal casting molding process until the process adjustment index of the metal casting molding process is greater than the process adjustment threshold; If the process adjustment index of the metal casting molding process is greater than the process adjustment threshold, adjustment parameters for adjusting the process optimization set of the metal casting molding process are collected, and the process optimization set of the metal casting molding process is adjusted based on the process optimization set of the metal casting molding process and the adjustment parameters, thereby updating the simulation process parameters of the metal casting molding process, generating a pre-production parameter preparation set of the metal casting molding process, transmitting the updated simulation process parameters of the metal casting molding process to the pre-production parameter preparation set of the metal casting molding process, and feeding back the pre-production parameter preparation set of the metal casting molding process in the form of a log, thereby completing the adjustment feedback of the intelligent control of residual stress in the metal casting molding process.

5. A method for controlling residual stress based on metal casting according to any one of claims 1 to 4, characterized in that: include: S1. Through the simulation process of metal casting, the simulation process parameters of the metal casting process and the basic parameters of the components to be cast are collected, and the residual stress risk assessment value of the metal casting process is analyzed by big data; S2. Compare the residual stress risk assessment value of the metal casting molding process with the residual stress risk assessment threshold. If the residual stress risk assessment value of the metal casting molding process is less than or equal to the residual stress risk assessment threshold, execute S4. If the residual stress risk assessment value of the metal casting molding process is greater than the residual stress risk assessment threshold, match and execute the process optimization set of the metal casting molding process, thereby evaluating the process optimization index of the metal casting molding process. S3. Compare the process optimization index of the metal casting molding process with the process optimization threshold. If the process optimization index of the metal casting molding process is greater than the process optimization threshold, update the simulation process parameters of the metal casting molding process and execute S4. If the process optimization index of the metal casting molding process is less than or equal to the process optimization threshold, adjust the process optimization set of the metal casting molding process, determine the process adjustment index of the metal casting molding process, and adjust and feedback the intelligent control of the residual stress of the metal casting molding process; S4. Collect simulation process parameters of the metal casting molding process and provide feedback on the simulation process parameters of the metal casting molding process.

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