Casting stress analysis method and system based on virtual simulation system

Abstract

The invention relates to the technical field of casting, in particular to a casting stress analysis method and system based on a virtual simulation system. The method comprises the steps that casting information is obtained and analyzed, an information analysis result is obtained, and a casting structure is determined according to the information analysis result; based on a virtual simulation model, casting simulation is conducted according to the casting structure, and a casting simulation result is obtained; determining a temperature field in the casting according to the casting simulation result; and according to the temperature field, thermal-structure coupling analysis is carried out, and the thermal stress in the casting is determined. And key features and potential stress concentration areas of the casting are identified, so that the accuracy of casting design and the reliability of simulation are ensured. Defects in the design are found, so that correction is carried out in the design stage. According to thermal-structure coupling analysis, temperature field data and mechanical behaviors of the casting are combined, and thermal stress distribution in the casting can be predicted more accurately.

Description

Technical Field

[0001] The present application relates to the field of casting technology, and in particular to a casting stress analysis method and system based on a virtual simulation system. Background Art

[0002] With the advancement of computing technology and virtual simulation tools, virtual simulation systems allow engineers to create detailed 3D models of castings and simulate the entire casting process on computers. From pouring to cooling, all links can be carried out in a virtual environment, allowing casting parameters to be optimized before actual production.

[0003] Accurate simulation of thermal stress in castings remains a major challenge in casting simulation. Thermal stress is mainly caused by temperature gradients during the cooling process of the casting. The internal stress caused by temperature differences may cause deformation, cracking or other defects in the casting. Therefore, accurate prediction of thermal stress at an early stage is crucial to avoid potential problems in the casting process. Summary of the invention

[0004] The present application provides a casting stress analysis method and system based on a virtual simulation system to solve the above problems.

[0005] In a first aspect, the present application provides a casting stress analysis method based on a virtual simulation system, the method comprising: Acquire and analyze casting information to obtain information analysis results, and determine the casting structure based on the information analysis results; Based on the virtual simulation model, according to the casting structure, a casting simulation is performed to obtain a casting simulation result; Determining the temperature field inside the casting according to the casting simulation results; Based on the temperature field, a thermal-structural coupling analysis is performed to determine the thermal stress inside the casting.

[0006] Through this solution, by collecting and analyzing casting information, the key features and potential stress concentration areas of the casting can be identified, providing a solid foundation for subsequent simulation and analysis, ensuring the accuracy of casting design and the reliability of simulation. Casting simulation can predict the flow and cooling process of molten metal, helping to evaluate the manufacturing feasibility of castings. Through simulation, defects in the design can be found and corrected in the design stage. By analyzing the temperature field, high-temperature and low-temperature areas can be identified, and the thermal stress and deformation of the casting during the cooling process can be predicted. Thermal-structural coupling analysis combines temperature field data with the mechanical behavior of the casting, and can more accurately predict the thermal stress distribution inside the casting. In summary, through precise modeling and simulation, thermal stress in castings can be predicted more accurately, improving the quality and reliability of castings. At the same time, the need for physical prototypes is reduced, saving time and cost, and improving the accuracy of the casting process.

[0007] Optionally, performing casting simulation according to the casting structure includes: Determine the runner position and the ingate position according to the casting structure; Performing virtual grid division on the casting according to the runner position and the ingate position to obtain a division result; Determining the structural characteristics of each unit grid according to the division result and the casting structure; According to the structural characteristics, simulation parameters are determined, and casting simulation is performed according to the simulation parameters.

[0008] Through this solution, choosing the right runner and ingate position is the key to ensure that the molten metal fills the mold smoothly and reduces defects. Through virtual simulation, different pouring schemes can be previewed and their impact on the quality of the casting can be evaluated, thereby optimizing the gating system design and reducing the scrap rate. Virtual meshing is to divide the casting model into many small units for simulation calculation. Through meshing, the accuracy and efficiency of the simulation can be improved and the reliability of the calculation results can be ensured. Analyzing the structural characteristics of each mesh unit helps to understand the cooling and solidification behavior of the casting in different areas, and helps to identify potential defective areas such as hot spots or cold shuts, so as to take corresponding measures to optimize the casting design. The determination of simulation parameters is the key to ensuring the accuracy of simulation results. Including pouring temperature, pouring speed, cooling conditions, etc. By accurately setting the simulation parameters, the actual casting process can be more realistically reflected and the reliability of the simulation results can be improved. Casting simulation can predict the flow pattern, cooling rate and temperature distribution of the molten metal. Through simulation, the impact of different pouring schemes on the quality of the casting can be evaluated, so as to select the best pouring strategy, reduce defects and improve the quality of the casting.

[0009] Optionally, performing virtual grid division on the casting according to the runner position and the ingate position includes: Determine the casting model structure and cooling structure according to the casting structure; Determining the overlap of the casting structure, the casting model structure and the cooling structure according to the runner position and the ingate position; According to the overlap condition, the casting structure, the casting model structure and the cooling structure are virtual meshed.

[0010] Through this solution, by establishing an accurate model of the casting and cooling system, a clear framework can be provided for meshing, which helps to ensure that the meshing can accurately reflect the geometric characteristics of the casting and the design of the cooling system, and lay a solid foundation for subsequent casting simulation and stress analysis. Correctly determining the location of the runner and ingate is crucial for the flow and filling efficiency of the molten metal. Through accurate location setting, the flow path of the molten metal can be optimized, the flow resistance can be reduced, the filling efficiency can be improved, and thus the defects of the casting can be reduced. Checking the overlap of the runner and ingate with the structure of the casting can ensure that the gating system does not conflict with the structure of the casting itself, which helps to avoid flow obstacles during the pouring process, ensure that the molten metal can smoothly fill every corner of the mold, and reduce defects such as insufficient pouring and cold shut. Virtual meshing is to divide the casting model into many small units for simulation calculation. Through meshing, the accuracy and efficiency of the simulation can be improved, and the reliability of the calculation results can be ensured. Meshing can also help identify potential defect areas, such as hot spots or cold shuts, so that corresponding measures can be taken to optimize the casting design.

[0011] Optionally, determining the runner position and the ingate position according to the casting structure includes: Determine the smooth area of ​​the casting according to the information analysis result; Determining a feasible runner and a feasible pouring gate according to the smooth area of ​​the casting; For each feasible runner and each feasible casting port, virtual simulation is used to simulate the feasible casting process to obtain the feasible casting result; Determining the cooling process of the casting with different feasible runners or different feasible casting gates according to the feasible casting results; According to the cooling process of the casting, the runner position and the gate position with the least cooling effect are determined.

[0012] Through this solution, by analyzing the geometric information of the casting, determining the smooth area helps to identify the smooth path of the molten metal flow. These areas usually have uniform wall thickness and fewer geometric mutations, which can reduce flow obstacles and turbulence during the pouring process, thereby improving filling efficiency and casting quality. Based on the smooth area, determining the feasible runner and ingate locations can ensure that the flow path of the molten metal from the ladle to the casting is optimal, which helps to avoid casting defects such as insufficient pouring, cold shut or slag inclusion caused by improper runner or ingate design. Through virtual simulation, the flow pattern, filling time and cooling rate of the molten metal, as well as possible defects, can be predicted, which helps to evaluate the advantages and disadvantages of different runner and ingate designs and provide a basis for subsequent decision-making. By analyzing the feasible casting results, the effects of different runners and ingates on the cooling process of the casting can be understood, which helps to identify the cooling mode that may cause thermal stress and defects, thereby optimizing the casting design. Finally, determining the runner and ingate locations with the least cooling effect can minimize thermal stress and casting defects and improve the overall quality and reliability of the casting. In addition, this also helps to reduce the costs of subsequent processing and repairs.

[0013] Optionally, determining the temperature field inside the casting according to the casting simulation result includes: Determine the casting temperature according to the information analysis result; Determining temperature changes according to the casting simulation results and the casting cooling process; The temperature field inside the casting is determined according to the casting temperature and the temperature variation.

[0014] Through this solution, determining the appropriate casting temperature helps to ensure the fluidity and filling capacity of the molten metal, thereby reducing casting defects such as insufficient pouring and cold shut. The choice of casting temperature also affects the cooling rate of the casting and the final thermal stress distribution. The casting simulation results provide process information on the flow of molten metal and filling of the casting, which helps to accurately predict the temperature changes of the casting during the pouring stage. By simulating the cooling process of the casting, the thermal stress and temperature distribution of the casting during the solidification and cooling stages can be predicted, which is crucial to understanding the cooling behavior of the casting. By combining the casting temperature and the temperature change data during the cooling process, the temperature field inside the casting can be accurately described, which is crucial for predicting thermal stress and preventing casting defects. Accurate temperature field data helps thermal-structural coupling analysis, thereby more accurately predicting the thermal stress distribution inside the casting and guiding the optimization of casting design. By analyzing the temperature field, areas that may cause deformation, cracking or other defects in the casting can be identified, so that measures can be taken in the design stage to prevent these defects.

[0015] Optionally, performing a thermal-structural coupling analysis according to the temperature field to determine the thermal stress inside the casting includes: Analyze the casting structure to determine whether it is a multi-casting simulation; If yes, determining a single casting region according to the casting structure and the information analysis result; For each single casting, analyzing the ingate position and the runner position to determine the proximal side stress and the distal side stress; Analyzing the cooling structure to determine the cooling effect; The thermal stress inside the casting is determined based on the adjacent side stress of each single casting, the distal side stress of each single casting and the cooling effect stress.

[0016] Through this solution, by analyzing the casting structure and determining whether the interaction of multiple castings needs to be considered, it helps to ensure that the simulation analysis can accurately reflect the heat transfer and stress distribution between multiple castings in the actual production process. Decomposing the multi-casting structure into a single casting area helps to simplify the analysis model, improve computational efficiency, and focus more on the independent thermal stress analysis of each casting. Analyzing the location of the gate and runner has an important impact on the flow and cooling of the molten metal. By optimizing these locations, thermal stress can be reduced and the quality of the casting can be improved. By analyzing the stress distribution on the adjacent side and the distal side, areas where thermal stress is concentrated can be identified, thereby guiding the optimization of casting design and reducing potential defects. Considering the impact of the cooling structure on the cooling process of the casting can help more accurately predict the thermal stress distribution during the cooling process, thereby optimizing the design of the cooling system and improving the quality of the casting. By comprehensively analyzing the adjacent side stress, the distal side stress and the cooling effect stress, the thermal stress distribution inside the casting can be obtained, which helps to predict the defects such as deformation and cracking that may occur in the casting during the cooling process, thereby guiding the optimization of the casting design and production process. Optionally, analyzing the cooling structure to determine the cooling effect force includes: Analyze the cooling structure to determine the geometric distribution, density and medium fluidity of the cooling channels; Determine the casting material according to the information analysis result; Determining the thermophysical properties and thermal conductivity characteristics of the material according to the casting material; Determining the casting shape according to the casting structure; The cooling effect force is determined according to the geometric distribution, the density, the fluidity of the medium, the thermophysical properties of the material, and the shape of the casting.

[0017] Through this solution, by analyzing the geometric distribution of cooling channels, we can understand how the cooling system interacts with the casting, thereby predicting the cooling efficiency and heat transfer rate, which helps to identify areas that may cause local overheating or undercooling. The density of cooling channels directly affects the cooling effect. High-density channels generally provide more uniform cooling, but may increase casting complexity and cost. Low-density channels may not provide sufficient cooling, resulting in reduced casting quality. Through CFD simulation, the flow pattern of the cooling medium, including flow rate, pressure distribution and temperature change, can be predicted, which helps to evaluate the performance of the cooling system and optimize the design of cooling channels. Selecting the right casting material is crucial to the quality and performance of the casting. The casting characteristics and thermophysical properties of different materials affect the cooling process and the final thermal stress distribution. The thermophysical properties of materials, such as thermal conductivity, specific heat capacity and thermal expansion coefficient, have an important influence on the temperature distribution and thermal stress during the cooling process of the casting. Understanding these properties helps to more accurately predict the behavior of the casting. The geometry of the casting affects the cooling efficiency. Complex shapes may lead to uneven cooling, while simple shapes may be easier to achieve uniform cooling. By combining the cooling structure geometry, density, medium fluidity, material thermophysical properties, and casting shape, the thermal stress distribution generated during cooling can be predicted, helping to identify high stress areas that may lead to casting defects.

[0018] Optionally, determining the thermal stress inside the casting according to the adjacent side stress of each single casting, the distal side stress of each single casting and the cooling effect stress comprises: Determine the temperature difference of each single casting according to the stress on the close side of each single casting and the stress on the far side of each single casting; Analyze the single casting area to determine the spacing distance between two adjacent single castings; Determining the temperature influence of adjacent castings according to the spacing distance, the thermophysical properties of the material and the heat conduction characteristics; The thermal stress inside the casting is determined based on the temperature difference, the temperature influence of the adjacent castings and the cooling effect.

[0019] Through this solution, by analyzing the temperature distribution on the adjacent and distal sides of a single casting, temperature gradients and potential areas of thermal stress concentration can be identified, thereby guiding the design and optimization of the cooling system. By analyzing the geometry of the casting and determining the spacing between adjacent castings, it is helpful to evaluate the thermal interaction and thermal stress transfer between castings, thereby optimizing the layout and cooling design of the casting. By considering the thermophysical properties and thermal conductivity characteristics of the casting material, the temperature impact between adjacent castings can be predicted, thereby optimizing the cooling strategy of the casting and preventing thermal stress concentration. By comprehensively analyzing the temperature difference, the temperature impact of adjacent castings and the cooling effect, the thermal stress distribution inside the casting can be more accurately predicted, thereby guiding the optimization of casting design and production processes and improving the quality and reliability of castings.

[0020] Optionally, the thermal stress inside the casting is determined according to the temperature difference, the temperature influence of the adjacent castings and the cooling effect, using the following formula:

[0021]

[0022] Among them, Δ T i ( x ) represents the temperature difference; Δ T ij ( x ) represents the temperature influence of the adjacent castings; E represents the Young's modulus of the casting material; σ i ( x ) represents the thermal stress inside the casting; α Represents the coefficient of thermal expansion.

[0023] Through this solution, information such as the geometric dimensions, material properties, and cooling system design of the castings are collected to provide basic data for subsequent simulation analysis. The entire casting process is simulated, including stages such as pouring, filling, and solidification, to predict the temperature distribution of the castings at different stages. According to the simulated temperature distribution, thermal analysis is performed to calculate the thermal stress distribution inside the castings, providing a data basis for subsequent thermal stress calculations. The temperature difference at each point inside the casting is calculated, that is, the difference between the actual temperature and the reference temperature (such as room temperature), which is one of the key parameters for thermal stress calculation. The influence of adjacent castings on the temperature of the current casting is analyzed, which is an important factor to be considered in multi-casting simulation and helps to predict the thermal stress distribution more accurately. The Young's modulus and thermal expansion coefficient of the casting material are obtained. These material properties are important parameters for calculating thermal stress and affect the thermal stress distribution of the casting. The thermal stress at each node is calculated using the given formula to obtain the thermal stress distribution diagram inside the casting, providing a basis for casting design and optimization. The thermal stress distribution diagram is analyzed to identify high stress areas and potential defect risks, providing guidance for the improvement of casting design and cooling systems.

[0024] In a second aspect, the present application provides a casting stress analysis system based on a virtual simulation system, which is used for: An information analysis module is used to obtain and analyze casting information, obtain information analysis results, and determine the casting structure based on the information analysis results; A casting simulation module, used to perform casting simulation based on the virtual simulation model and the casting structure to obtain a casting simulation result; A temperature field determination module, used to determine the temperature field inside the casting according to the casting simulation result; The stress analysis module is used to perform thermal-structural coupling analysis according to the temperature field to determine the thermal stress inside the casting.

[0025] Optionally, when performing casting simulation according to the casting structure, the casting simulation module is used to: Determine the runner position and the ingate position according to the casting structure; Performing virtual grid division on the casting according to the runner position and the ingate position to obtain a division result; Determining the structural characteristics of each unit grid according to the division result and the casting structure; According to the structural characteristics, simulation parameters are determined, and casting simulation is performed according to the simulation parameters.

[0026] Optionally, when the casting simulation module performs virtual grid division on the casting according to the runner position and the ingate position, it is used to: Determine the casting model structure and cooling structure according to the casting structure; Determining the overlap of the casting structure, the casting model structure and the cooling structure according to the runner position and the ingate position; According to the overlap condition, the casting structure, the casting model structure and the cooling structure are virtual meshed.

[0027] Optionally, when the casting simulation module determines the runner position and the ingate position according to the casting structure, it is used to: Determine the smooth area of ​​the casting according to the information analysis result; Determining a feasible runner and a feasible pouring gate according to the smooth area of ​​the casting; For each feasible runner and each feasible casting port, virtual simulation is used to simulate the feasible casting process to obtain the feasible casting result; Determining the cooling process of the casting with different feasible runners or different feasible casting gates according to the feasible casting results; According to the cooling process of the casting, the runner position and the gate position with the least cooling effect are determined.

[0028] Optionally, when the temperature field determination module determines the temperature field inside the casting according to the casting simulation result, it is used to: Determine the casting temperature according to the information analysis result; Determining temperature changes according to the casting simulation results and the casting cooling process; The temperature field inside the casting is determined according to the casting temperature and the temperature variation.

[0029] Optionally, the stress analysis module performs a thermal-structural coupling analysis based on the temperature field to determine the thermal stress inside the casting, and is used to: Analyze the casting structure to determine whether it is a multi-casting simulation; If yes, determining a single casting region according to the casting structure and the information analysis result; For each single casting, analyzing the ingate position and the runner position to determine the proximal side stress and the distal side stress; Analyzing the cooling structure to determine the cooling effect; The thermal stress inside the casting is determined based on the adjacent side stress of each single casting, the distal side stress of each single casting and the cooling effect stress.

[0030] Optionally, when the stress analysis module analyzes the cooling structure to determine the cooling effect stress, it is used to: Analyze the cooling structure to determine the geometric distribution, density and medium fluidity of the cooling channels; Determine the casting material according to the information analysis result; Determining the thermophysical properties and thermal conductivity characteristics of the material according to the casting material; Determining the casting shape according to the casting structure; The cooling effect force is determined according to the geometric distribution, the density, the fluidity of the medium, the thermophysical properties of the material, and the shape of the casting.

[0031] Optionally, when determining the thermal stress inside the casting according to the adjacent side stress of each single casting, the distal side stress of each single casting and the cooling effect stress, the stress analysis module is used to: Determine the temperature difference of each single casting according to the stress on the close side of each single casting and the stress on the far side of each single casting; Analyze the single casting area to determine the spacing distance between two adjacent single castings; Determining the temperature influence of adjacent castings according to the spacing distance, the thermophysical properties of the material and the heat conduction characteristics; The thermal stress inside the casting is determined based on the temperature difference, the temperature influence of the adjacent castings and the cooling effect.

[0032] Optionally, the stress analysis module determines the thermal stress inside the casting according to the temperature difference, the temperature influence of the adjacent castings and the cooling effect, using the following formula:

[0033]

[0034] Among them, Δ T i ( x ) represents the temperature difference; Δ T ij ( x ) represents the temperature influence of the adjacent castings; E represents the Young's modulus of the casting material; σ i ( x ) represents the thermal stress inside the casting; α Represents the coefficient of thermal expansion. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, a brief introduction will be given below to the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative labor.

[0036] Figure 1 A schematic diagram of an application scenario provided for an embodiment of the present application; Figure 2 A flowchart of a casting stress analysis method based on a virtual simulation system provided in one embodiment of the present application; Figure 3 A schematic diagram of the structure of a casting stress analysis system based on a virtual simulation system is provided in one embodiment of the present application. DETAILED DESCRIPTION

[0037] In order to make the purpose, technical scheme and advantages of the embodiments of the present application clearer, the technical scheme in the embodiments of the present application will be clearly and completely described below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of this application.

[0038] In addition, the term "and / or" in this article is only a description of the association relationship of associated objects, indicating that there can be three relationships. For example, A and / or B can represent: A exists alone, A and B exist at the same time, and B exists alone. In addition, the character " / " in this article, unless otherwise specified, generally means that the associated objects before and after are in an "or" relationship.

[0039] The embodiments of the present application are further described in detail below in conjunction with the drawings in the specification.

[0040] With the advancement of computing technology and virtual simulation tools, virtual simulation systems allow engineers to create detailed 3D models of castings and simulate the entire casting process on computers. From pouring to cooling, all links can be carried out in a virtual environment, allowing casting parameters to be optimized before actual production.

[0041] Accurate simulation of thermal stress in castings remains a major challenge in casting simulation. Thermal stress is mainly caused by temperature gradients during the cooling process of the casting. The internal stress caused by temperature differences may cause deformation, cracking or other defects in the casting. Therefore, accurate prediction of thermal stress at an early stage is crucial to avoid potential problems in the casting process.

[0042] Based on this, the present application provides a casting stress analysis method and system based on a virtual simulation system, which obtains and analyzes casting information, obtains information analysis results, and determines the casting structure according to the information analysis results; based on the virtual simulation model, casting simulation is performed according to the casting structure to obtain casting simulation results; according to the casting simulation results, the temperature field inside the casting is determined; according to the temperature field, thermal-structural coupling analysis is performed to determine the thermal stress inside the casting. By collecting and analyzing casting information, the key features and potential stress concentration areas of the casting can be identified, providing a solid foundation for subsequent simulation and analysis, and ensuring the accuracy of casting design and the reliability of simulation. Casting simulation can predict the flow and cooling process of molten metal and help evaluate the manufacturing feasibility of castings. Through simulation, defects in the design can be found, so that corrections can be made in the design stage. By analyzing the temperature field, high temperature areas and low temperature areas can be identified, and the thermal stress and deformation of the casting during the cooling process can be predicted. Thermal-structural coupling analysis combines temperature field data with the mechanical behavior of the casting, and can more accurately predict the thermal stress distribution inside the casting. In summary, accurate modeling and simulation can more accurately predict thermal stresses in castings, improve the quality and reliability of castings, reduce the need for physical prototypes, save time and costs, and improve the accuracy of the casting process.

[0043] Figure 1 A schematic diagram of an application scenario provided by the present application is used when performing thermal stress analysis inside a casting in a casting simulation. Specifically, the method provided by the present application is applied to any server, and the server interacts with a drawing database. The casting information is collected and analyzed through the drawing database, and the key features and potential stress concentration areas of the casting can be identified, providing a solid foundation for subsequent simulation and analysis, and ensuring the accuracy of the casting design and the reliability of the simulation. The casting simulation can predict the flow and cooling process of the molten metal, and help evaluate the manufacturing feasibility of the casting. Through simulation, defects in the design can be found, so that corrections can be made in the design stage. By analyzing the temperature field, high temperature areas and low temperature areas can be identified, and the thermal stress and deformation of the casting during the cooling process can be predicted. The thermal-structural coupling analysis combines the temperature field data with the mechanical behavior of the casting, and can more accurately predict the thermal stress distribution inside the casting. In summary, through precise modeling and simulation, the thermal stress in the casting can be more accurately predicted, and the quality and reliability of the casting can be improved. At the same time, the need for physical prototypes is reduced, time and cost are saved, and the accuracy of the casting process is improved. The specific implementation method can refer to the following embodiments.

[0044] Figure 2 This is a flowchart of a casting stress analysis method based on a virtual simulation system provided in an embodiment of the present application. The method of this embodiment can be applied to the server in the above scenario. Figure 2As shown, the method includes: S201, acquiring and analyzing casting information, obtaining information analysis results, and determining the casting structure based on the information analysis results.

[0045] Casting information can be detailed data about the casting, including the size, shape, design drawings, material type, thermophysical properties, etc. of the casting.

[0046] The information analysis results can be the data and conclusions obtained after processing and analyzing the casting information, such as the wall thickness distribution of the casting, stress concentration area, material property analysis, etc.

[0047] The casting structure can be the three-dimensional geometric shape and internal structure of the casting. The casting structure determines the function and mechanical properties of the casting and is an important basis for casting simulation and stress analysis.

[0048] Specifically, the geometric information of the casting, including the shape, size and design features of the casting, is obtained through the drawing database. And the data related to the casting material, such as thermal conductivity, specific heat capacity, density and thermal expansion coefficient and other thermophysical properties, are determined. Using this information, analysis is performed through specialized software tools to determine the key structural features of the casting, such as wall thickness, transition areas and potential stress concentration points.

[0049] S202, based on the virtual simulation model and according to the casting structure, performing casting simulation to obtain a casting simulation result.

[0050] The virtual simulation model can be a three-dimensional model of a casting constructed on a computer, which is used to simulate and analyze the casting process. The virtual simulation model can include the casting's geometric information, material properties, pouring system, cooling system, etc.

[0051] Casting simulation can be a virtual simulation model that simulates the entire process of molten metal being poured from a ladle into a mold and cooled and solidified. It can predict the flow pattern, temperature distribution and potential defects in the casting.

[0052] The casting simulation results can be the data and graphic output obtained after the casting simulation is completed, such as the flow trajectory of the molten metal, the cooling rate, the temperature gradient, etc.

[0053] Specifically, a virtual simulation model is established based on the acquired casting information using casting simulation software. The location and size of the gating system (including runners, ingates, and risers) and the cooling system of the casting (such as cooling water channels) are set in the model. The casting is meshed, that is, the casting is divided into many small units for simulation calculation. Simulation parameters such as pouring speed, pouring temperature, and cooling conditions are set according to the geometric characteristics and material properties of the casting.

[0054] S203. Determine the temperature field inside the casting according to the casting simulation result.

[0055] The interior of a casting can be the space and structure inside the casting. In the stress analysis of castings, the temperature distribution and stress distribution inside the casting are mainly reflected.

[0056] The temperature field can be the temperature distribution inside or on the surface of the casting.

[0057] Specifically, run the casting simulation, observe the flow and cooling process of the molten metal, and record the temperature changes. Based on the simulation results, draw a temperature distribution map inside the casting to identify areas with large temperature gradients.

[0058] S204. Perform thermal-structural coupling analysis based on the temperature field to determine the thermal stress inside the casting.

[0059] Thermal-structural coupling analysis can be an analysis method that combines thermal analysis and structural analysis to realize the analysis of material deformation and internal stress caused by temperature changes.

[0060] Thermal stress can be internal stress inside a casting due to temperature gradients, which may cause the casting to deform, crack or fail.

[0061] Specifically, use the thermal-structural coupling analysis software to import the temperature field data into the casting model. Set the mechanical boundary conditions, such as the fixing method and load conditions of the casting. Perform thermal-structural coupling analysis to calculate the stress distribution inside the casting caused by temperature changes. Analyze the results of the thermal-structural coupling analysis to determine the stress concentration area and the size of the thermal stress inside the casting. According to the design and use requirements of the casting, evaluate whether the thermal stress is within an acceptable range.

[0062] Through this solution, by collecting and analyzing casting information, the key features and potential stress concentration areas of the casting can be identified, providing a solid foundation for subsequent simulation and analysis, ensuring the accuracy of casting design and the reliability of simulation. Casting simulation can predict the flow and cooling process of molten metal, helping to evaluate the manufacturing feasibility of castings. Through simulation, defects in the design can be found and corrected in the design stage. By analyzing the temperature field, high-temperature and low-temperature areas can be identified, and the thermal stress and deformation of the casting during the cooling process can be predicted. Thermal-structural coupling analysis combines temperature field data with the mechanical behavior of the casting, and can more accurately predict the thermal stress distribution inside the casting. In summary, through precise modeling and simulation, thermal stress in castings can be predicted more accurately, improving the quality and reliability of castings. At the same time, the need for physical prototypes is reduced, saving time and cost, and improving the accuracy of the casting process.

[0063] In some embodiments, the runner position and the gate position are determined according to the structure of the casting; the casting is virtually meshed according to the runner position and the gate position to obtain a meshing result; the structural characteristics of each unit mesh are determined according to the meshing result and the structure of the casting; simulation parameters are determined according to the structural characteristics, and casting simulation is performed according to the simulation parameters.

[0064] The runner location may be the portion of the gating system used to direct the molten metal from the ladle into the mold.

[0065] The ingate location may be the entry point of the runner into the casting pattern.

[0066] Virtual meshing can be to divide the casting model into many small units to facilitate simulation calculation.

[0067] Structural features can be the geometric characteristics and internal structure of the casting model, including wall thickness, shape, connection parts, reinforcement ribs, etc.

[0068] The simulation parameters may be various parameters that need to be set during virtual simulation, such as pouring temperature, pouring speed, mold temperature, cooling medium temperature, cooling efficiency, etc.

[0069] Specifically, according to the structural characteristics of the casting, the design of the gating system is determined, including the location, number and size of the runner, as well as the location and shape of the inner gate. These design parameters will affect the flow speed and direction of the molten metal, and then affect the cooling rate and temperature distribution of the casting. The casting model is meshed using computer-aided engineering (CAE) software to decompose the casting model into many small unit grids. The quality of meshing directly affects the accuracy of the simulation results, so it is necessary to select the appropriate mesh type and size according to the geometric complexity of the casting and the analysis requirements. The structural characteristics of each unit grid, such as wall thickness, shape and the relationship between adjacent units, are analyzed, which will affect the flow and cooling process of the molten metal. According to the geometric characteristics of the casting, material properties and the design of the gating system, simulation parameters such as pouring temperature, pouring speed, cooling conditions, etc. are set. These parameters will affect the fidelity of the simulation and the reliability of the results. Run the casting simulation software to simulate the entire process of the molten metal being poured from the ladle into the mold and cooling and solidifying according to the set parameters and meshing results. During the simulation process, the software will calculate the flow rate, temperature change and solidification process of the molten metal to generate simulation results.

[0070] Through this solution, choosing the right runner and ingate position is the key to ensure that the molten metal fills the mold smoothly and reduces defects. Through virtual simulation, different pouring schemes can be previewed and their impact on the quality of the casting can be evaluated, thereby optimizing the gating system design and reducing the scrap rate. Virtual meshing is to divide the casting model into many small units for simulation calculation. Through meshing, the accuracy and efficiency of the simulation can be improved and the reliability of the calculation results can be ensured. Analyzing the structural characteristics of each mesh unit helps to understand the cooling and solidification behavior of the casting in different areas, and helps to identify potential defective areas such as hot spots or cold shuts, so as to take corresponding measures to optimize the casting design. The determination of simulation parameters is the key to ensuring the accuracy of simulation results. Including pouring temperature, pouring speed, cooling conditions, etc. By accurately setting the simulation parameters, the actual casting process can be more realistically reflected and the reliability of the simulation results can be improved. Casting simulation can predict the flow pattern, cooling rate and temperature distribution of the molten metal. Through simulation, the impact of different pouring schemes on the quality of the casting can be evaluated, so as to select the best pouring strategy, reduce defects and improve the quality of the casting.

[0071] In some embodiments, the casting model structure and the cooling structure are determined according to the casting structure; the overlap of the casting structure, the casting model structure and the cooling structure is determined according to the runner position and the inner gate position; and the casting structure, the casting model structure and the cooling structure are virtually meshed according to the overlap.

[0072] A casting model structure is the three-dimensional geometry and internal structure of a casting, usually created using computer-aided design (CAD) software.

[0073] A cooling structure may be a system designed into a casting mold to control the cooling rate of the casting.

[0074] The coincidence condition can be the spatial relationship between the casting model structure, runner and ingate position.

[0075] Specifically, an accurate three-dimensional model of the casting is established through CAD software. Then, according to the shape and size of the casting, the cooling system is designed, including the layout and size of the cooling water channel. According to the design requirements of the casting and the design principles of the gating system, the positions of the runners and ingates are determined. The selection of these positions will affect the flow and filling efficiency of the molten metal. In the casting model, the positions of the runners and ingates are superimposed with the geometric shape of the casting itself to check whether they conflict with the geometric features of the casting (such as wall thickness, ribs, holes, etc.), which helps to ensure that the gating system can effectively guide the molten metal into the mold without interfering with the casting structure. Using finite element analysis (FEA) software, the casting model, runners and cooling structures are meshed. The purpose of meshing is to discretize the continuous casting model into a finite number of units for numerical calculation. In the meshing process, the structural characteristics of the casting, the shape of the runners and cooling water channels, and the material properties need to be considered. Different meshing strategies may be required for different parts of the casting model. For example, in the runner and ingate areas, a finer mesh may be required to capture the flow details of the molten metal; while in other parts of the casting, a coarser mesh can be used to reduce the amount of calculation. In addition, the quality of the mesh, such as the shape and size of the unit, needs to be considered to ensure the accuracy of the calculation results. Set the meshing parameters according to the geometric characteristics of the casting, material properties, and the design of the gating system. These parameters may include the density of the mesh, the type of unit (such as tetrahedron, hexahedron, etc.), the quality index of the mesh, etc. Setting appropriate meshing parameters is crucial to ensure the accuracy of the simulation results and the efficiency of the calculation.

[0076] Through this solution, by establishing an accurate model of the casting and cooling system, a clear framework can be provided for meshing, which helps to ensure that the meshing can accurately reflect the geometric characteristics of the casting and the design of the cooling system, and lay a solid foundation for subsequent casting simulation and stress analysis. Correctly determining the location of the runner and ingate is crucial for the flow and filling efficiency of the molten metal. Through accurate location setting, the flow path of the molten metal can be optimized, the flow resistance can be reduced, the filling efficiency can be improved, and thus the defects of the casting can be reduced. Checking the overlap of the runner and ingate with the structure of the casting can ensure that the gating system does not conflict with the structure of the casting itself, which helps to avoid flow obstacles during the pouring process, ensure that the molten metal can smoothly fill every corner of the mold, and reduce defects such as insufficient pouring and cold shut. Virtual meshing is to divide the casting model into many small units for simulation calculation. Through meshing, the accuracy and efficiency of the simulation can be improved, and the reliability of the calculation results can be ensured. Meshing can also help identify potential defect areas, such as hot spots or cold shuts, so that corresponding measures can be taken to optimize the casting design.

[0077] In some embodiments, based on the information analysis results, a smooth area of ​​the casting is determined; based on the smooth area of ​​the casting, a feasible runner and a feasible casting gate are determined; for each feasible runner and each feasible casting gate, a feasible casting process is simulated using virtual simulation to obtain a feasible casting result; based on the feasible casting result, a cooling process of the casting with different feasible runners or different feasible casting gates is determined; based on the cooling process of the casting, a runner position and an inner gate position with minimal cooling effect are determined.

[0078] Smooth areas of a casting may be areas on the surface of the casting that have no sharp turns, bumps or abrupt changes.

[0079] A feasible runner can be a metal liquid flow channel pre-set in the casting design according to the structure and size of the casting.

[0080] The pouring gate is the point of entry for the molten metal to enter the casting. The location and size of the pouring gate have an important influence on the flow direction and speed of the molten metal.

[0081] A feasible casting process can be the entire process simulated in virtual simulation, in which the molten metal flows from the ladle through the runner into the casting and cools and solidifies.

[0082] The casting cooling process can be the process of gradually cooling the casting from a high temperature state to room temperature after casting. The temperature distribution and cooling rate inside the casting will directly affect the quality and performance of the casting.

[0083] Specifically, the geometric information of the casting is obtained through CAD software, including the size, shape and design features of the casting. Thermophysical property data related to the casting material, such as thermal conductivity, specific heat capacity, density and thermal expansion coefficient, are collected. The structural characteristics of the casting are analyzed to identify possible thermal stress concentration areas and key design parameters. Based on the geometric information of the casting, the surface and smooth areas of the casting are identified, where the molten metal flows smoothly during the casting process. The wall thickness distribution of the casting is analyzed to determine the areas with uniform wall thickness and no sharp turns, which are more suitable as the locations of runners and ingates. Based on the geometric characteristics of the casting and the flow characteristics of the molten metal, the possible runner paths and ingates are determined. Consider the length, diameter and direction of the runner, as well as the shape and size of the ingate to ensure that the molten metal can fully fill the casting. Using casting simulation software, the flow and cooling process of the molten metal are simulated according to the determined runner and ingate locations. The simulation results, including the flow trajectory of the molten metal, filling time and cooling rate, are analyzed to evaluate the feasibility of the runner and ingate. According to the simulation results, analyze the influence of different runner and ingate positions on the cooling process of the casting. Determine the cooling rate, temperature gradient and thermal stress distribution, and evaluate the deformation, cracking and other defects that may occur in the casting during the cooling process. Compare the cooling effects of different runner and ingate positions, and select the position with the least influence on the cooling of the casting. Consider the overall design and manufacturing requirements of the casting to determine the final runner and ingate positions.

[0084] Through this solution, by analyzing the geometric information of the casting, determining the smooth area helps to identify the smooth path of the molten metal flow. These areas usually have uniform wall thickness and fewer geometric mutations, which can reduce flow obstacles and turbulence during the pouring process, thereby improving filling efficiency and casting quality. Based on the smooth area, determining the feasible runner and ingate locations can ensure that the flow path of the molten metal from the ladle to the casting is optimal, which helps to avoid casting defects such as insufficient pouring, cold shut or slag inclusion caused by improper runner or ingate design. Through virtual simulation, the flow pattern, filling time and cooling rate of the molten metal, as well as possible defects, can be predicted, which helps to evaluate the advantages and disadvantages of different runner and ingate designs and provide a basis for subsequent decision-making. By analyzing the feasible casting results, the effects of different runners and ingates on the cooling process of the casting can be understood, which helps to identify the cooling mode that may cause thermal stress and defects, thereby optimizing the casting design. Finally, determining the runner and ingate locations with the least cooling effect can minimize thermal stress and casting defects and improve the overall quality and reliability of the casting. In addition, this also helps to reduce the costs of subsequent processing and repairs.

[0085] In some embodiments, the temperature field inside the casting is determined based on the casting simulation results, including: determining the casting temperature based on the information analysis results; determining the temperature change based on the casting simulation results and the casting cooling process; determining the temperature field inside the casting based on the casting temperature and the temperature change.

[0086] The pouring temperature may be the temperature to which the molten metal is heated during the casting process to ensure that it has sufficient fluidity and filling capacity to fill the entire casting mold.

[0087] The temperature variation can refer to the temperature variation of the inside and surface of the casting over time, starting from the casting temperature, through the filling, solidification and cooling stages during the casting process.

[0088] Specifically, the appropriate casting temperature is determined according to the material properties of the casting and the casting process requirements. This step usually involves the analysis of the melting point, fluidity, filling capacity and castability of the casting material of the molten metal. Considering the heat loss during the casting process and the cooling rate of the molten metal, the casting temperature is adjusted to optimize the casting quality. Using virtual simulation software, the casting process of the molten metal is simulated, including the flow of the runner, the inner gate and the inside of the casting. Analyze the simulation results to determine the temperature change of the molten metal during the casting process and the temperature gradient of the casting during the cooling process. Considering the material properties and heat conduction characteristics of the casting, the temperature distribution and thermal stress of the casting during the cooling process are predicted. The casting temperature and the temperature change data during the cooling process are input into the thermal analysis model. Use finite element analysis (FEA) or computational fluid dynamics (CFD) methods to simulate the temperature field inside the casting. This usually involves establishing a heat conduction equation and considering boundary conditions and initial conditions. Based on the simulation results, draw a temperature distribution diagram inside the casting and analyze the uniformity and thermal gradient of the temperature field. Evaluate the impact of the temperature field on the structure of the casting, including possible deformation, cracking or other defects.

[0089] Through this solution, determining the appropriate casting temperature helps to ensure the fluidity and filling capacity of the molten metal, thereby reducing casting defects such as insufficient pouring and cold shut. The choice of casting temperature also affects the cooling rate of the casting and the final thermal stress distribution. The casting simulation results provide process information on the flow of molten metal and filling of the casting, which helps to accurately predict the temperature changes of the casting during the pouring stage. By simulating the cooling process of the casting, the thermal stress and temperature distribution of the casting during the solidification and cooling stages can be predicted, which is crucial to understanding the cooling behavior of the casting. By combining the casting temperature and the temperature change data during the cooling process, the temperature field inside the casting can be accurately described, which is crucial for predicting thermal stress and preventing casting defects. Accurate temperature field data helps thermal-structural coupling analysis, thereby more accurately predicting the thermal stress distribution inside the casting and guiding the optimization of casting design. By analyzing the temperature field, areas that may cause deformation, cracking or other defects in the casting can be identified, so that measures can be taken in the design stage to prevent these defects.

[0090] In some embodiments, a thermal-structural coupling analysis is performed based on the temperature field to determine the thermal stress inside the casting, including: analyzing the casting structure to determine whether it is a multi-casting simulation; if so, determining a single casting area based on the casting structure and information analysis results; for each single casting, analyzing the gate position and the runner position to determine the adjacent side stress and the distal side stress; analyzing the cooling structure to determine the cooling effect stress; determining the thermal stress inside the casting based on the adjacent side stress of each single casting, the distal side stress of each single casting and the cooling effect stress.

[0091] Multi-casting simulation can be used to simulate and analyze multiple castings simultaneously during the casting simulation process.

[0092] A single casting region can be a region where the entire casting system is decomposed into independent casting units for analysis in a multi-casting simulation.

[0093] The close side stress can be the stress experienced by the area of ​​the casting close to the side of the ingate during the solidification and cooling process of the casting.

[0094] The away side stress can be the stress experienced by the area of ​​the casting away from the side of the ingate during the solidification and cooling process of the casting.

[0095] Cooling effect stress can be additional stress caused by the design and operation of the cooling system (such as cooling water channels, fans, etc.).

[0096] Specifically, evaluate the design and manufacturing requirements of the casting to determine whether multiple castings need to be simulated. Multi-casting simulation is usually used to analyze the interaction between castings and the performance of the overall casting system. If it is determined to be a multi-casting simulation, further analyze the connection mode and interaction between the castings to provide a basis for the subsequent single casting analysis. In the multi-casting simulation, the overall casting is divided into several single casting areas according to the geometric characteristics of the casting and the casting process. These areas can be independent castings or parts of the casting. Establish a separate model for each single casting area to facilitate separate analysis. Analyze the geometric structure of each single casting to determine the optimal location of the gate and runner. The selection of these locations should take into account the flow characteristics of the molten metal and the filling requirements of the casting. Use casting simulation software to simulate the flow of molten metal in a single casting and analyze the effects of the gate and runner on the internal flow and cooling of the casting. Through thermal-structural coupling analysis, determine the stress distribution of each single casting on the adjacent side (the side close to the gate) and the distal side (the side away from the gate). Analyze how these stresses change over time, especially during the solidification and cooling stages. Consider the design of the casting cooling structure, such as cooling channels, fans or other cooling devices, and analyze the impact of these structures on the thermal stress during the cooling of the casting. Determine the cooling effect stress, which is the additional thermal stress caused by the cooling structure design. Combine the adjacent side stress, the distant side stress and the cooling effect stress of each single casting, and use the thermal-structural coupling analysis software to calculate the thermal stress distribution inside the casting. Analyze the impact of thermal stress distribution on the structural integrity and performance of the casting, and identify possible high stress areas and potential defects.

[0097] Through this solution, by analyzing the casting structure, determining whether the interaction of multiple castings needs to be considered, it helps to ensure that the simulation analysis can accurately reflect the heat transfer and stress distribution between multiple castings in the actual production process. Decomposing the multi-casting structure into a single casting area helps to simplify the analysis model, improve the calculation efficiency, and focus more on the independent thermal stress analysis of each casting. The location of the gate and runner has an important impact on the flow and cooling of the molten metal. By optimizing these locations, thermal stress can be reduced and the quality of the casting can be improved. By analyzing the stress distribution on the adjacent side and the far side, the area where thermal stress is concentrated can be identified, thereby guiding the optimization of casting design and reducing potential defects. Considering the influence of the cooling structure on the cooling process of the casting helps to more accurately predict the thermal stress distribution during the cooling process, thereby optimizing the design of the cooling system and improving the quality of the casting. By comprehensively analyzing the adjacent side stress, the far side stress and the cooling effect stress, the thermal stress distribution inside the casting can be obtained, which helps to predict the defects such as deformation and cracking that may occur in the casting during the cooling process, thereby guiding the optimization of the casting design and production process.

[0098] In some embodiments, the cooling structure is analyzed to determine the cooling effect force, including: analyzing the cooling structure to determine the geometric distribution, density and medium fluidity of the cooling channel; determining the casting material based on the information analysis results; determining the material's thermophysical properties and thermal conductivity characteristics based on the casting material; determining the casting shape based on the casting structure; determining the cooling effect force based on the geometric distribution, density, medium fluidity, material thermophysical properties, and casting shape.

[0099] The geometric distribution can be the spatial layout and arrangement of the cooling channels in the casting, which determines the contact area and path of the cooling medium and the casting, thereby affecting the cooling efficiency and heat transfer rate.

[0100] Density can be In cooling structure analysis, density usually refers to the number or distribution density of cooling channels.

[0101] Medium fluidity can be the flow characteristics of the cooling medium (such as water, air, etc.) in the cooling channel.

[0102] The casting material may be a metallic material used to manufacture the casting.

[0103] Thermophysical properties of materials can be thermal related properties of materials, such as thermal conductivity, specific heat capacity, thermal expansion coefficient, etc.

[0104] Thermal conductivity is the ability of a material to transfer heat.

[0105] Casting shape can be the geometric shape and internal structure of the casting.

[0106] Specifically, use CAD software or simulation software to analyze the geometry and location of the cooling channels. Including the length, diameter, shape and distribution pattern of the channels. Calculate the density of the cooling channels, that is, the number of cooling channels per unit volume. Density affects cooling efficiency and heat transfer rate. Use CFD (computational fluid dynamics) simulation to analyze the flow characteristics of the cooling medium (such as water or air) in the cooling channels, including flow rate, pressure distribution and temperature change. Select the appropriate casting material according to the design requirements and performance goals of the casting. Collect the thermophysical property data of the casting material, including thermal conductivity, specific heat capacity, density and thermal expansion coefficient. Analyze the geometry of the casting, including wall thickness, size and characteristics, which will affect heat transfer and cooling efficiency. Combined with the geometric distribution of the cooling channels, density, medium fluidity, thermophysical properties of the casting material and the shape of the casting, use thermal analysis software to simulate the entire cooling process. Through thermal-structural coupling analysis, calculate the thermal stress distribution inside the casting during the cooling process. Evaluate the impact of cooling effect stress on the structural integrity and performance of the casting, and identify possible high stress areas and potential defects.

[0107] Through this solution, by analyzing the geometric distribution of cooling channels, we can understand how the cooling system interacts with the casting, thereby predicting the cooling efficiency and heat transfer rate, which helps to identify areas that may cause local overheating or undercooling. The density of cooling channels directly affects the cooling effect. High-density channels generally provide more uniform cooling, but may increase casting complexity and cost. Low-density channels may not provide sufficient cooling, resulting in reduced casting quality. Through CFD simulation, the flow pattern of the cooling medium, including flow rate, pressure distribution and temperature change, can be predicted, which helps to evaluate the performance of the cooling system and optimize the design of cooling channels. Selecting the right casting material is crucial to the quality and performance of the casting. The casting characteristics and thermophysical properties of different materials affect the cooling process and the final thermal stress distribution. The thermophysical properties of materials, such as thermal conductivity, specific heat capacity and thermal expansion coefficient, have an important influence on the temperature distribution and thermal stress during the cooling process of the casting. Understanding these properties helps to more accurately predict the behavior of the casting. The geometry of the casting affects the cooling efficiency. Complex shapes may lead to uneven cooling, while simple shapes may be easier to achieve uniform cooling. By combining the cooling structure geometry, density, medium fluidity, material thermophysical properties, and casting shape, the thermal stress distribution generated during cooling can be predicted, helping to identify high stress areas that may lead to casting defects.

[0108] In some embodiments, the temperature difference of each single casting is determined based on the adjacent side stress of each single casting and the distal side stress of each single casting; the single casting area is analyzed to determine the spacing distance between two adjacent single castings; the temperature influence of adjacent castings is determined based on the spacing distance, material thermophysical properties and heat conduction characteristics; the thermal stress inside the casting is determined based on the temperature difference, the temperature influence of adjacent castings and the cooling effect.

[0109] Temperature difference can be the temperature difference between different parts of the casting or at different time points. Temperature difference is the main cause of thermal stress, which will cause thermal expansion and contraction of the material, thereby generating internal stress.

[0110] The spacing distance may be the spatial distance between adjacent castings in a multi-casting system.

[0111] The temperature influence of adjacent castings can be the influence of the thermal state (such as temperature, heat flow, etc.) of one casting on the thermal state of the adjacent casting.

[0112] Specifically, through thermal analysis, the temperature distribution of each single casting during the cooling process is calculated. Analyzing the temperature difference between the adjacent side and the distant side of each single casting helps to understand the effect of temperature gradient on thermal stress. Use CAD software or simulation software to analyze the geometric structure of the casting and determine the spacing distance between two adjacent single castings. Evaluate the effect of spacing distance on heat transfer and thermal stress distribution. Consider the effect of spacing distance on heat transfer and analyze the thermal interaction between adjacent castings. Combine the thermophysical properties and thermal conductivity characteristics of the casting material to predict the temperature effect between adjacent castings. Combine the temperature difference, the temperature effect of adjacent castings and the cooling effect, and use thermal-structural coupling analysis software to calculate the thermal stress distribution inside the casting. Analyze the effect of thermal stress distribution on the structural integrity and performance of the casting, and identify possible high stress areas and potential defects.

[0113] Through this solution, by analyzing the temperature distribution on the adjacent and distal sides of a single casting, temperature gradients and potential areas of thermal stress concentration can be identified, thereby guiding the design and optimization of the cooling system. By analyzing the geometry of the casting and determining the spacing between adjacent castings, it is helpful to evaluate the thermal interaction and thermal stress transfer between castings, thereby optimizing the layout and cooling design of the casting. By considering the thermophysical properties and thermal conductivity characteristics of the casting material, the temperature impact between adjacent castings can be predicted, thereby optimizing the cooling strategy of the casting and preventing thermal stress concentration. By comprehensively analyzing the temperature difference, the temperature impact of adjacent castings and the cooling effect, the thermal stress distribution inside the casting can be more accurately predicted, thereby guiding the optimization of casting design and production processes and improving the quality and reliability of castings.

[0114] In some embodiments, the thermal stress inside the casting is determined based on the temperature difference, the temperature influence of adjacent castings, and the cooling effect, using the following formula (1):

[0115] (1) Among them, Δ T i ( x ) represents the temperature difference; Δ T ij ( x ) represents the temperature influence of the adjacent castings; E represents the Young's modulus of the casting material; σ i ( x ) represents the thermal stress inside the casting; α Represents the coefficient of thermal expansion.

[0116] Specifically, thermal analysis is performed based on the simulated temperature distribution to calculate the thermal stress distribution inside the casting. Using finite element analysis (FEA) software, the casting model is divided into meshes for thermal stress calculation. At each node of the casting model, the temperature difference is calculated, that is, the difference between the temperature at the node and its reference temperature (such as room temperature). For each casting node, the temperature influence of the adjacent casting is calculated. This usually involves considering the contribution of the temperature field of the adjacent casting to the temperature of the current casting node. The temperature influence of the adjacent casting is accumulated to the temperature difference of the current casting. The Young's modulus and thermal expansion coefficient of the casting material are obtained from the material database. Ensure that these material properties match the actual material and temperature conditions of the casting. The thermal stress at each node is calculated using the given formula (2). Repeat the calculation on the entire casting model to obtain the thermal stress distribution map inside the casting. Analyze the thermal stress distribution map to identify high stress areas and potential defect risks.

[0117] Through this solution, information such as the geometric dimensions, material properties, and cooling system design of the castings are collected to provide basic data for subsequent simulation analysis. The entire casting process is simulated, including stages such as pouring, filling, and solidification, to predict the temperature distribution of the castings at different stages. According to the simulated temperature distribution, thermal analysis is performed to calculate the thermal stress distribution inside the castings, providing a data basis for subsequent thermal stress calculations. The temperature difference at each point inside the casting is calculated, that is, the difference between the actual temperature and the reference temperature (such as room temperature), which is one of the key parameters for thermal stress calculation. The influence of adjacent castings on the temperature of the current casting is analyzed, which is an important factor to be considered in multi-casting simulation and helps to predict the thermal stress distribution more accurately. The Young's modulus and thermal expansion coefficient of the casting material are obtained. These material properties are important parameters for calculating thermal stress and affect the thermal stress distribution of the casting. The thermal stress at each node is calculated using the given formula to obtain the thermal stress distribution diagram inside the casting, providing a basis for casting design and optimization. The thermal stress distribution diagram is analyzed to identify high stress areas and potential defect risks, providing guidance for the improvement of casting design and cooling systems.

[0118] Figure 3 A structural diagram of a casting stress analysis system based on a virtual simulation system is provided in one embodiment of the present application. Figure 3 As shown, the casting stress analysis system 300 based on the virtual simulation system of this embodiment includes: an information analysis module 301 , a casting simulation module 302 , a temperature field determination module 303 , and a stress analysis module 304 .

[0119] The information analysis module 301 is used to obtain and analyze casting information, obtain information analysis results, and determine the casting structure according to the information analysis results; A casting simulation module 302 is used to perform casting simulation based on the virtual simulation model and the casting structure to obtain a casting simulation result; A temperature field determination module 303 is used to determine the temperature field inside the casting according to the casting simulation result; The stress analysis module 304 is used to perform a thermal-structural coupling analysis based on the temperature field to determine the thermal stress inside the casting.

[0120] Optionally, when performing casting simulation according to the casting structure, the casting simulation module 302 is used to: Determine the runner position and the ingate position according to the casting structure; Performing virtual grid division on the casting according to the runner position and the ingate position to obtain a division result; Determining the structural characteristics of each unit grid according to the division result and the casting structure; According to the structural characteristics, simulation parameters are determined, and casting simulation is performed according to the simulation parameters.

[0121] Optionally, when the casting simulation module 302 performs virtual grid division on the casting according to the runner position and the ingate position, it is used to: Determine the casting model structure and cooling structure according to the casting structure; Determining the overlap of the casting structure, the casting model structure and the cooling structure according to the runner position and the ingate position; According to the overlap condition, the casting structure, the casting model structure and the cooling structure are virtual meshed.

[0122] Optionally, when the casting simulation module 302 determines the runner position and the ingate position according to the casting structure, it is used to: Determine the smooth area of ​​the casting according to the information analysis result; Determining a feasible runner and a feasible pouring gate according to the smooth area of ​​the casting; For each feasible runner and each feasible casting port, virtual simulation is used to simulate the feasible casting process to obtain the feasible casting result; Determining the cooling process of the casting with different feasible runners or different feasible casting gates according to the feasible casting results; According to the cooling process of the casting, the runner position and the gate position with the least cooling effect are determined.

[0123] Optionally, when the temperature field determination module 303 determines the temperature field inside the casting according to the casting simulation result, it is used to: Determine the casting temperature according to the information analysis result; Determining temperature changes according to the casting simulation results and the casting cooling process; The temperature field inside the casting is determined according to the casting temperature and the temperature variation.

[0124] Optionally, the stress analysis module 304 performs a thermal-structural coupling analysis based on the temperature field to determine the thermal stress inside the casting, and is used to: Analyze the casting structure to determine whether it is a multi-casting simulation; If yes, determining a single casting region according to the casting structure and the information analysis result; For each single casting, analyzing the ingate position and the runner position to determine the proximal side stress and the distal side stress; Analyzing the cooling structure to determine the cooling effect; The thermal stress inside the casting is determined based on the adjacent side stress of each single casting, the distal side stress of each single casting and the cooling effect stress.

[0125] Optionally, when the stress analysis module 304 analyzes the cooling structure to determine the cooling effect stress, it is used to: Analyze the cooling structure to determine the geometric distribution, density and medium fluidity of the cooling channels; Determine the casting material according to the information analysis result; Determining the thermophysical properties and thermal conductivity characteristics of the material according to the casting material; Determining the casting shape according to the casting structure; The cooling effect force is determined according to the geometric distribution, the density, the fluidity of the medium, the thermophysical properties of the material, and the shape of the casting.

[0126] Optionally, when the stress analysis module 304 determines the thermal stress inside the casting according to the adjacent side stress of each single casting, the distal side stress of each single casting and the cooling effect stress, it is used to: Determine the temperature difference of each single casting according to the stress on the close side of each single casting and the stress on the far side of each single casting; Analyze the single casting area to determine the spacing distance between two adjacent single castings; Determining the temperature influence of adjacent castings according to the spacing distance, the thermophysical properties of the material and the heat conduction characteristics; The thermal stress inside the casting is determined based on the temperature difference, the temperature influence of the adjacent castings and the cooling effect.

[0127] Optionally, the stress analysis module 304 determines the thermal stress inside the casting according to the temperature difference, the temperature influence of the adjacent castings and the cooling effect, using the following formula:

[0128]

[0129] Among them, Δ T i ( x ) represents the temperature difference; Δ T ij ( x ) represents the temperature influence of the adjacent castings; E represents the Young's modulus of the casting material; σ i ( x ) represents the thermal stress inside the casting; α Represents the coefficient of thermal expansion.

[0130] The system of this embodiment can be used to execute the method of any of the above embodiments. The implementation principles and technical effects are similar and will not be described in detail here.

Claims

1. A casting stress analysis method based on a virtual simulation system, characterized in that: include: Acquire and analyze casting information to obtain information analysis results, and determine the casting structure based on the information analysis results; Based on the virtual simulation model, according to the casting structure, a casting simulation is performed to obtain a casting simulation result; Determining the temperature field inside the casting according to the casting simulation results; Based on the temperature field, a thermal-structural coupling analysis is performed to determine the thermal stress inside the casting.

2. The method according to claim 1, characterized in that The casting simulation is performed according to the casting structure, including: Determine the runner position and the ingate position according to the casting structure; Performing virtual grid division on the casting according to the runner position and the ingate position to obtain a division result; Determining the structural characteristics of each unit grid according to the division result and the casting structure; According to the structural characteristics, simulation parameters are determined, and casting simulation is performed according to the simulation parameters.

3. The method according to claim 2, characterized in that The virtual grid division of the casting according to the runner position and the ingate position includes: Determine the casting model structure and cooling structure according to the casting structure; Determining the overlap of the casting structure, the casting model structure and the cooling structure according to the runner position and the ingate position; According to the overlap condition, the casting structure, the casting model structure and the cooling structure are virtual meshed.

4. The method according to claim 3, characterized in that Determining the runner position and the ingate position according to the casting structure includes: Determine the smooth area of ​​the casting according to the information analysis result; Determining a feasible runner and a feasible pouring gate according to the smooth area of ​​the casting; For each feasible runner and each feasible casting port, virtual simulation is used to simulate the feasible casting process to obtain the feasible casting result; Determining the cooling process of the casting with different feasible runners or different feasible casting gates according to the feasible casting results; According to the cooling process of the casting, the runner position and the gate position with the least cooling effect are determined.

5. The method according to claim 4, characterized in that Determining the temperature field inside the casting according to the casting simulation result includes: Determine the casting temperature according to the information analysis result; Determining temperature changes according to the casting simulation results and the casting cooling process; The temperature field inside the casting is determined according to the casting temperature and the temperature variation.

6. The method according to claim 5, characterized in that The step of performing a thermal-structural coupling analysis based on the temperature field to determine the thermal stress inside the casting includes: Analyze the casting structure to determine whether it is a multi-casting simulation; If yes, determining a single casting region according to the casting structure and the information analysis result; For each single casting, analyzing the ingate position and the runner position to determine the proximal side stress and the distal side stress; Analyzing the cooling structure to determine the cooling effect; The thermal stress inside the casting is determined based on the adjacent side stress of each single casting, the distal side stress of each single casting and the cooling effect stress.

7. The method according to claim 6, characterized in that The analyzing the cooling structure to determine the cooling effect force includes: Analyze the cooling structure to determine the geometric distribution, density and medium fluidity of the cooling channels; Determine the casting material according to the information analysis result; Determining the thermophysical properties and thermal conductivity characteristics of the material according to the casting material; Determining the casting shape according to the casting structure; The cooling effect force is determined according to the geometric distribution, the density, the fluidity of the medium, the thermophysical properties of the material, and the shape of the casting.

8. The method according to claim 7, characterized in that The step of determining the thermal stress inside the casting according to the adjacent side stress of each single casting, the distal side stress of each single casting and the cooling effect stress comprises: Determine the temperature difference of each single casting according to the stress on the close side of each single casting and the stress on the far side of each single casting; Analyze the single casting area to determine the spacing distance between two adjacent single castings; Determining the temperature influence of adjacent castings according to the spacing distance, the thermophysical properties of the material and the heat conduction characteristics; The thermal stress inside the casting is determined based on the temperature difference, the temperature influence of the adjacent castings and the cooling effect.

9. The method according to claim 8, characterized in that The thermal stress inside the casting is determined according to the temperature difference, the temperature influence of the adjacent castings and the cooling effect, using the following formula: ， Among them, Δ T i ( x ) represents the temperature difference; Δ T ij ( x ) represents the temperature influence of the adjacent castings; E represents the Young's modulus of the casting material; σ i ( x ) represents the thermal stress inside the casting; α Represents the coefficient of thermal expansion.

10. A casting stress subsystem based on a virtual simulation system, characterized in that: include: An information analysis module is used to obtain and analyze casting information, obtain information analysis results, and determine the casting structure based on the information analysis results; A casting simulation module, used to perform casting simulation based on the virtual simulation model and the casting structure to obtain a casting simulation result; A temperature field determination module, used to determine the temperature field inside the casting according to the casting simulation result; The stress analysis module is used to perform thermal-structural coupling analysis according to the temperature field to determine the thermal stress inside the casting.

Images