Casting shrinkage cavity defect prediction method and system based on virtual simulation technology

Abstract

The invention relates to the technical field of casting, in particular to a casting shrinkage cavity defect prediction method and system based on a virtual simulation technology. The method comprises the following steps: acquiring casting planning information, analyzing the casting planning information, and determining simulation parameters; performing analogue simulation according to the simulation parameters to obtain a simulation result, and determining a shrinkage cavity condition according to the simulation result; obtaining casting demand information, analyzing the casting demand information, and determining expected flatness; according to the shrinkage condition, the simulation parameters are adjusted, and according to the adjusted simulation parameters, the steps are repeated until the simulation result meets the expected flatness. And a possible shrinkage cavity area can be accurately identified. These zones typically appear where the temperature drops faster or where the cooling is uneven. Therefore, clear reference is provided for subsequent process adjustment. The quality standards of the castings in appearance and function are determined according to the actual purposes of the castings and customer requirements.

Description

Technical Field

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

[0002] Virtual simulation technology can predict key factors such as heat flow, stress, and deformation of castings during the casting process through computer simulation, thereby identifying possible defects in advance, optimizing the casting process, and reducing experimental costs and trial-and-error processes in production. Shrinkage is a common defect in the casting process, which refers to the voids formed inside or on the surface of the casting due to uneven cooling or poor metal flow. Shrinkage defects not only affect the appearance quality of the casting, but also seriously reduce its mechanical properties and even cause the failure of the casting.

[0003] In existing simulation methods, although simulation technology can predict possible defects in the casting process, how to effectively adjust simulation parameters based on these simulation results to optimize the casting process in order to improve the overall level of casting manufacturing and ultimately achieve the desired casting quality is still a key challenge facing the industry. Summary of the invention

[0004] The present application provides a casting shrinkage defect prediction method and system based on virtual simulation technology to solve the above problems.

[0005] In a first aspect, the present application provides a method for predicting shrinkage defects in castings based on virtual simulation technology, the method comprising: S1. Obtain casting planning information, analyze the casting planning information, and determine simulation parameters; S2. Performing simulation according to the simulation parameters to obtain simulation results, and determining shrinkage conditions according to the simulation results; S3. Obtain casting demand information, analyze the casting demand information, and determine the desired flatness; S4. According to the shrinkage situation, the simulation parameters are adjusted, and according to the adjusted simulation parameters, step S2 is repeated until the simulation results meet the desired flatness.

[0006] Through this solution, according to the specific design of the casting (such as the location of the gate, riser, runner, etc.) and material properties, key simulation parameters (such as casting temperature, flow rate, cooling rate, etc.) are determined, providing a basis for subsequent simulation and optimization. Through in-depth analysis of casting planning information, problems that may affect casting quality can be discovered in advance. For example, dead corners may cause poor metal flow, thereby causing shrinkage holes, and these potential problems will be reflected in subsequent simulations. By analyzing the simulation results, possible shrinkage areas can be accurately identified. The simulation can provide the probability and location of shrinkage holes, providing a basis for the next step of optimization. The visualization of simulation results helps technicians understand the potential defects and temperature changes in the casting process more intuitively, thereby providing a clear reference for subsequent process adjustments. According to the actual use of the casting and customer needs, the quality standards of the casting in appearance and function are clarified. By analyzing the shrinkage situation (such as too fast cooling, too high casting speed, etc.), the simulation parameters are accurately adjusted. For example, appropriately increase the casting temperature, reduce the casting speed, or change the cooling method to optimize the temperature field distribution to ensure that there is no excessive temperature difference inside the casting, thereby effectively avoiding the formation of shrinkage cavities. Each adjusted simulation will give a new simulation result. Based on the new simulation results, technicians continue to analyze the defects of the castings, especially shrinkage cavities and surface quality, to ensure that these problems are effectively solved.

[0007] Optionally, analyzing the casting planning information and determining simulation parameters includes: Analyze the casting planning information to determine the gate position, runner position and riser position; Obtain casting information and determine casting properties and casting structure; The simulation parameters are determined according to the casting properties, the casting structure, the gate position, the runner position and the riser position.

[0008] Through this solution, the location and size of the gate, runner and riser are determined. This information directly affects the flow of molten metal and the cooling process of the casting. Identify hot spots, thin walls and stress concentration areas in the casting structure, which are prone to defects such as shrinkage and cracks during the casting process. Determine the melting point, thermal conductivity, shrinkage rate and other properties of the selected material. These properties will affect the solidification process and final dimensional accuracy of the casting. The appropriate casting temperature can ensure that the molten metal has good fluidity and filling properties, reducing the formation of shrinkage and cracks. Controlling the casting speed can avoid the molten metal flowing too fast or too slow, thereby reducing defects such as under-casting and cold shut. Choosing the appropriate cooling method can control the cooling rate of the casting and reduce shrinkage and deformation.

[0009] Optionally, the simulation parameters include casting temperature, and before determining the shrinkage situation according to the simulation results, the method further includes: Determine the casting partitioning conditions according to the casting structure; Acquiring casting data according to the casting partitioning conditions; Analyzing the casting data to determine temperature changes during the casting process; A special area is determined based on the temperature change and the casting temperature.

[0010] Through this solution, complex castings are decomposed into zones that are easier to manage and analyze. Through partitioning, the heat flow and solidification behavior of each zone can be simulated and analyzed more accurately, thus providing a basis for subsequent temperature change analysis and identification of special zones. Collect actual casting data related to each partition, such as casting temperature, casting speed, etc. These data are essential for simulating the flow and solidification process of molten metal, and help improve the accuracy and reliability of simulation. By analyzing the casting data, understand the temperature changes of the casting during the casting process. It helps to identify high-risk areas where shrinkage cavities may form and provide a basis for identifying special areas. Identify special areas where shrinkage cavities may form due to temperature changes and casting temperature. These areas may require special casting process adjustments or shrinkage compensation measures to reduce the formation of defects.

[0011] Optionally, determining simulation parameters according to the casting properties, the casting structure, the gate position, the runner position and the riser position includes: Determining structural changes in the special area according to the casting structure; Determine the casting dead angle according to the structural changes; Determining a dead corner casting speed of the casting dead corner according to the gate position and the runner position; Determining an initial casting speed according to the dead angle casting speed, the gate position and the runner position; Determining a casting cooling method according to the structural changes; Determining the casting temperature and casting pressure according to the initial casting speed and the casting cooling method; The casting temperature, the casting pressure and the initial casting speed are determined as the simulation parameters.

[0012] Through this solution, special areas in the casting, such as hot spots, thin walls, complex shapes, etc., are identified, and the structural changes of these areas during the casting process are analyzed. This helps to predict the casting defects that may occur in these areas, such as shrinkage cavities, cracks, etc. The casting speed of the dead corner area is determined according to the design of the gate and runner. The appropriate casting speed helps the molten metal to fully fill the dead corner and reduce defects. According to the casting speed of the dead corner and other related factors, the initial casting speed of the entire casting is determined. This is the key to ensure that the molten metal flows evenly throughout the mold. According to the structural changes and material properties of the casting, the appropriate cooling method is selected. The choice of cooling method has an important impact on the stress and deformation of the casting. According to the initial casting speed and the cooling method of the casting, the casting temperature and pressure are determined. These parameters have a direct impact on the fluidity of the molten metal and the solidification process of the casting. The above-determined parameters are used as simulation parameters for the simulation of the casting process. These parameters will directly affect the accuracy of the simulation and the prediction of defects.

[0013] Optionally, adjusting the simulation parameters according to the shrinkage situation includes: According to the structural changes, the casting structure is subjected to a cell-by-cell simulation disassembly to obtain a casting unit; Determine the defect location according to the shrinkage cavity situation, and analyze the shrinkage cavity situation to determine the shrinkage cavity size and actual temperature change of each defect location; Determining a related position according to the defect position; Determining an adjustment area according to the associated position and the defect position; Determining the expected temperature for resolving the shrinkage cavity at the defect location according to the shrinkage cavity size and the actual temperature change; The simulation parameters are adjusted according to the expected temperature.

[0014] Through this solution, complex casting structures are broken down into smaller, more manageable units. These units can be simulated independently, which helps to more accurately analyze the local behavior of the casting, such as hot spots, shrinkage holes, etc. Identify the location of shrinkage defects in the casting and analyze the specific conditions of these defects. By determining the size of the shrinkage holes and the actual temperature change, it can provide a basis for subsequent defect resolution. Identify other locations related to the defect location that may affect or be affected by the defect. The determination of associated locations helps to fully understand the cause of the defect. Determine specific areas that need to be adjusted in order to resolve the shrinkage defect. The adjustment area may include the defect location itself and the locations associated with it. Based on the size of the shrinkage hole and the actual temperature change, determine a desired temperature range to resolve the shrinkage problem. This temperature range will be used to guide the adjustment of simulation parameters. Based on the determined desired temperature, adjust simulation parameters such as casting temperature, casting speed, cooling method, etc. to achieve the purpose of resolving shrinkage holes.

[0015] Optionally, adjusting the simulation parameters according to the expected temperature includes: According to the gate position, determine the gate diameter; Based on the gate diameter, analyzing the casting structure, and determining the gate adjustment position; Determining a casting position according to the casting temperature, the initial casting speed and the expected temperature; Determining a gate position adjustment plan according to the casting position and the gate adjustment position; The simulation parameters are adjusted according to the gate position adjustment scheme.

[0016] Through this solution, the appropriate gate diameter is determined according to the location of the gate and the geometry of the casting. The size of the gate diameter affects the flow rate and flow of the molten metal, which in turn affects the filling and solidification process of the casting. Analyze the effect of the gate diameter on the structure of the casting, and determine the location where the gate may need to be adjusted based on the analysis results. This helps to optimize the gating system and reduce the formation of defects. Determine the best casting position of the molten metal based on the casting temperature, initial casting speed and expected temperature. This helps to ensure that the molten metal can fill the mold evenly and reduce the formation of defects. Determine the adjustment plan for the gate position based on the casting position and the location where the gate may need to be adjusted. This helps to optimize the gating system and improve the quality of the casting. According to the adjustment plan for the gate position, adjust the simulation parameters such as casting temperature, casting speed, cooling method, etc. This helps to improve the accuracy of the simulation and the quality of the casting.

[0017] Optionally, analyzing the casting structure based on the gate diameter to determine the gate adjustment position includes: Based on the gate diameter, analyzing the casting structure, determining a suitable position that satisfies the gate diameter; Analyze the surrounding structures of the suitable location to determine the difficulty of grinding; According to the grinding difficulty, it is determined whether to use the appropriate position as the gate adjustment position.

[0018] Through this solution, ensure that the location of the gate can meet the requirements of the gate diameter, while taking into account the structural characteristics of the casting, such as wall thickness, shape and thermal joints. This helps to avoid uneven metal flow or defect formation caused by improper gate location. Evaluate the impact of the casting structure around the gate on the grinding process and the difficulty of grinding. This helps to improve efficiency and quality in the subsequent manufacturing process. Decide whether the gate position needs to be adjusted based on the difficulty of grinding to ensure the quality of the casting and the efficiency of production.

[0019] Optionally, adjusting the simulation parameters according to the gate position adjustment scheme includes: According to the shrinkage cavity situation, determine the cooling point position; Determine a riser adjustment plan according to the gate position and the cooling point position; The simulation parameters are adjusted according to the gate position adjustment scheme and the riser adjustment scheme.

[0020] Through this solution, shrinkage cavities in castings are analyzed and the location of cooling points is determined so that shrinkage defects can be reduced or eliminated by controlling cooling. According to the location of gates and cooling points, the design of risers is adjusted to ensure that the molten metal can fully fill the mold and reduce defects. According to the adjustment plan of gates and risers, the simulation parameters are adjusted to optimize the quality of castings.

[0021] Optionally, determining the associated position according to the defect position includes: Determining actual heating conditions of the defect location according to the casting speed and the initial casting temperature; Determining, according to the desired flatness and the properties of the casting, a desired heat for achieving the desired flatness under the influence of the properties of the casting; Determining the impact range of the defect position according to the temperature change and the expected heat; According to the impact range, an associated position is determined.

[0022] Through this solution, the actual heating conditions of the defect location during the casting process are understood, providing a basis for subsequent temperature control and defect prevention. Determine the expected heat that the casting should reach during the cooling process in order to achieve the desired casting flatness. Determine the temperature influence range around the defect location so that appropriate measures can be taken. Analyze the temperature gradient around the defect location and determine the affected heat transfer area. Determine the influence range of the defect location based on the temperature change and the expected heat. Based on the influence range of the defect location, determine the associated position so that the optimization of the casting can be considered as a whole.

[0023] In a second aspect, the present application provides a casting shrinkage defect prediction system based on virtual simulation technology, the system comprising: An information analysis module, used to obtain casting planning information, analyze the casting planning information, and determine simulation parameters; A shrinkage cavity determination module is used to perform simulation according to the simulation parameters to obtain simulation results, and determine the shrinkage cavity situation according to the simulation results; A demand analysis module, used to obtain casting demand information, analyze the casting demand information, and determine the expected flatness; The adjustment module is used to adjust the simulation parameters according to the shrinkage situation, and repeatedly execute the shrinkage determination module according to the adjusted simulation parameters until the simulation result meets the expected flatness.

[0024] Optionally, when the information analysis module analyzes the casting planning information and determines the simulation parameters, it is used to: Analyze the casting planning information to determine the gate position, runner position and riser position; Obtain casting information and determine casting properties and casting structure; The simulation parameters are determined according to the casting properties, the casting structure, the gate position, the runner position and the riser position.

[0025] Optionally, the simulation parameters include casting temperature, and the casting shrinkage defect prediction system further includes a regional analysis module for: Determine the casting partitioning conditions according to the casting structure; Acquiring casting data according to the casting partitioning conditions; Analyzing the casting data to determine temperature changes during the casting process; A special area is determined based on the temperature change and the casting temperature.

[0026] Optionally, when the information analysis module determines the simulation parameters according to the casting properties, the casting structure, the gate position, the runner position and the riser position, it is used to: Determining structural changes in the special area according to the casting structure; Determine the casting dead angle according to the structural changes; Determining a dead corner casting speed of the casting dead corner according to the gate position and the runner position; Determining an initial casting speed according to the dead angle casting speed, the gate position and the runner position; Determining a casting cooling method according to the structural changes; Determining the casting temperature and casting pressure according to the initial casting speed and the casting cooling method; The casting temperature, the casting pressure and the initial casting speed are determined as the simulation parameters.

[0027] Optionally, when the adjustment module adjusts the simulation parameters according to the shrinkage situation, it is used to: According to the structural changes, the casting structure is subjected to a cell-by-cell simulation disassembly to obtain a casting unit; Determine the defect location according to the shrinkage cavity situation, and analyze the shrinkage cavity situation to determine the shrinkage cavity size and actual temperature change of each defect location; Determining a related position according to the defect position; Determining an adjustment area according to the associated position and the defect position; Determining the expected temperature for resolving the shrinkage cavity at the defect location according to the shrinkage cavity size and the actual temperature change; The simulation parameters are adjusted according to the expected temperature.

[0028] Optionally, when the adjustment module adjusts the simulation parameter according to the expected temperature, it is used to: According to the gate position, determine the gate diameter; Based on the gate diameter, analyzing the casting structure, and determining the gate adjustment position; Determining a casting position according to the casting temperature, the initial casting speed and the expected temperature; Determining a gate position adjustment plan according to the casting position and the gate adjustment position; The simulation parameters are adjusted according to the gate position adjustment scheme.

[0029] Optionally, when the adjustment module analyzes the casting structure based on the gate diameter and determines the gate adjustment position, it is used to: Based on the gate diameter, analyzing the casting structure, determining a suitable position that satisfies the gate diameter; Analyze the surrounding structures of the suitable location to determine the difficulty of grinding; According to the grinding difficulty, it is determined whether to use the appropriate position as the gate adjustment position.

[0030] Optionally, when the adjustment module adjusts the simulation parameters according to the gate position adjustment scheme, it is used to: According to the shrinkage cavity situation, determine the cooling point position; Determine a riser adjustment plan according to the gate position and the cooling point position; The simulation parameters are adjusted according to the gate position adjustment scheme and the riser adjustment scheme.

[0031] Optionally, when the adjustment module determines the associated position according to the defect position, it is used to: Determining actual heating conditions of the defect location according to the casting speed and the initial casting temperature; Determining, according to the desired flatness and the properties of the casting, a desired heat for achieving the desired flatness under the influence of the properties of the casting; Determining the impact range of the defect position according to the temperature change and the expected heat; According to the impact range, an associated position is determined. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] 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.

[0033] Figure 1 A schematic diagram of an application scenario provided for an embodiment of the present application; Figure 2 A flowchart of a casting shrinkage defect prediction method based on virtual simulation technology provided in one embodiment of the present application; Figure 3 A schematic diagram of the structure of a casting shrinkage defect prediction system based on virtual simulation technology provided in one embodiment of the present application. DETAILED DESCRIPTION

[0034] 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.

[0035] 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.

[0036] The embodiments of the present application are further described in detail below in conjunction with the drawings in the specification.

[0037] Virtual simulation technology can predict key factors such as heat flow, stress, and deformation of castings during the casting process through computer simulation, thereby identifying possible defects in advance, optimizing the casting process, and reducing experimental costs and trial-and-error processes in production. Shrinkage is a common defect in the casting process, which refers to the voids formed inside or on the surface of the casting due to uneven cooling or poor metal flow. Shrinkage defects not only affect the appearance quality of the casting, but also seriously reduce its mechanical properties and even cause the failure of the casting.

[0038] In the existing simulation methods, although simulation technology can predict defects, how to effectively adjust the simulation parameters according to the simulation results to optimize the casting process, so as to effectively reduce or eliminate shrinkage defects and achieve the desired casting quality, is still a problem to be solved.

[0039] Based on this, the present application provides a casting shrinkage defect prediction method and system based on virtual simulation technology, S1. Obtain casting planning information, analyze casting planning information, and determine simulation parameters; S2. Perform simulation according to simulation parameters to obtain simulation results, and determine shrinkage conditions according to simulation results; S3. Obtain casting demand information, analyze casting demand information, and determine expected flatness; S4. Adjust simulation parameters according to shrinkage conditions, and repeat step S2 according to the adjusted simulation parameters until the simulation results meet the expected flatness. According to the specific design of the casting (such as the positions of the gate, riser, runner, etc.) and material properties, key simulation parameters (such as casting temperature, flow rate, cooling rate, etc.) are determined, which provides a basis for subsequent simulation and optimization. These parameters directly determine the reliability of the simulation results. Through in-depth analysis of casting planning information, problems that may affect casting quality can be discovered in advance. For example, dead corner positions may cause poor metal flow, thereby causing shrinkage, and these potential problems will be reflected in subsequent simulations. By analyzing the simulation results, possible shrinkage areas can be accurately identified. These areas usually appear as places where the temperature drops faster or where the cooling is uneven. The simulation can provide the probability and location of shrinkage cavities, providing a basis for the next step of optimization. The visualization of simulation results helps technicians to more intuitively understand the potential defects and temperature changes in the casting process, thereby providing a clear reference for subsequent process adjustments. The acquisition and analysis of casting demand information is the key to determining the desired flatness. The desired flatness usually involves the smoothness, shape and dimensional accuracy of the casting surface. According to the actual use of the casting and customer needs, the quality standards of the casting in appearance and function are clarified. By analyzing the shrinkage situation (such as reasons such as too fast cooling and too high casting speed), the simulation parameters are accurately adjusted. For example, appropriately increase the casting temperature, reduce the casting speed, or optimize the temperature field distribution by changing the cooling method to ensure that there is no excessive temperature difference inside the casting, thereby effectively avoiding the formation of shrinkage cavities. Each adjusted simulation will give a new simulation result. Based on the new simulation results, technicians continue to analyze the defects of the casting, especially shrinkage cavities and surface quality, to ensure that these problems are effectively solved.

[0040] Figure 1A schematic diagram of an application scenario provided for this application is used when simulating a casting. Specifically, the method provided by this application is applied to any server, and the server interacts with the design database to obtain casting planning information and simulation parameters from the design database. According to the specific design of the casting (such as the location of the gate, riser, runner, etc.) and material properties, the key simulation parameters (such as casting temperature, flow rate, cooling rate, etc.) are determined, which provides a basis for subsequent simulation and optimization. These parameters directly determine the reliability of the simulation results. Through in-depth analysis of the casting planning information, problems that may affect the casting quality can be discovered in advance. By analyzing the simulation results, possible shrinkage areas can be accurately identified. These areas are usually manifested as places where the temperature drops faster or where the cooling is uneven. The simulation can provide the probability and location of shrinkage, providing a basis for the next step of optimization. The visualization of the simulation results helps technicians to more intuitively understand the potential defects and temperature changes in the casting process, thereby providing a clear reference for subsequent process adjustments. The expected flatness usually involves the smoothness, shape and dimensional accuracy of the casting surface. According to the actual use of castings and customer needs, the quality standards of castings in appearance and function are clarified. By analyzing the shrinkage situation (such as too fast cooling, too high casting speed, etc.), the simulation parameters are accurately adjusted. This effectively avoids the formation of shrinkage. Each adjusted simulation will give a new simulation result. Based on the new simulation results, the technicians continue to analyze the defects of the castings, especially shrinkage and surface quality, to ensure that these problems are effectively solved.

[0041] By precisely controlling the simulation parameters, optimizing the temperature distribution and metal flow, the shrinkage defects in the castings can be significantly reduced, and the intrinsic quality of the castings can be improved. The desired flatness target can eventually be met, and the casting surface will be smoother and free of obvious defects, meeting customer and usage requirements. Through continuous iteration and optimization, the accuracy of the casting process is improved, the process of experimentation and trial and error is reduced, the production cost is reduced, and the consistency and reliability of the castings are improved. The specific implementation method can refer to the following embodiments.

[0042] Figure 2 This is a flowchart of a casting shrinkage defect prediction method based on virtual simulation technology provided in an embodiment of the present application. The method of this embodiment can be applied to the server in the above scenario. Figure 2 As shown, the method includes: S1. Obtain casting planning information, analyze casting planning information, and determine simulation parameters.

[0043] The casting planning information is obtained from the design database. The casting planning information may be information for planning the casting production process according to product design requirements, material properties, production equipment and process conditions, etc., during the casting design stage.

[0044] Simulation parameters can be variables used to control simulation behavior during the simulation process, such as casting temperature, casting speed, cooling rate, material properties, boundary conditions, etc.

[0045] Specifically, it is necessary to first obtain the casting's geometric information, material properties, dimensional data, etc. from the CAD model or casting design. In particular, the location, size and other parameters of important casting channels such as gates, runners and risers. According to the casting's geometric shape, analyze whether the casting has complex structural features, such as dead corners, thin-walled parts, etc. These structural features may cause poor metal flow and shrinkage defects. By analyzing the casting planning information and combining the material properties of the casting, determine the key simulation parameters such as casting temperature, flow rate, cooling method, etc. These parameters play a vital role in the results of the simulation.

[0046] S2. Perform simulation according to the simulation parameters to obtain simulation results, and determine the shrinkage situation according to the simulation results; Simulation is the use of computer software to simulate an actual or hypothetical system to predict how the system will behave under different conditions.

[0047] The simulation results can be the data output after the simulation is completed, reflecting the behavior and state of the system during the simulation process. The simulation results can include temperature field, flow field, solidification process, stress distribution, etc.

[0048] Shrinkage porosity can be a cavity that forms inside or on the surface of a casting, usually due to shrinkage of the molten metal during cooling.

[0049] Specifically, the simulation parameters are obtained from the design database. After obtaining the simulation parameters, virtual simulation is performed based on these parameters. The simulation can accurately simulate the phenomena such as heat flow, flow, temperature change, etc. in the casting process, and determine the occurrence of shrinkage cavities by analyzing the results. Use professional casting simulation software (such as ProCAST, FLOW-3D, etc.) to simulate the casting process. By inputting the simulation parameters determined in the first step, such as casting temperature, flow rate, cooling method, etc., the thermal-fluid-mechanical coupling simulation of the casting is performed. Through the simulation results, the temperature distribution, flow state, solidification process, etc. of the casting can be viewed. In the simulation, the possible shrinkage location is determined by judging whether the temperature gradient and metal flow inside the casting are uniform. In the simulation results, areas with excessive temperature gradients are identified, which are often high-incidence areas of shrinkage cavities. By predicting the location and size of shrinkage cavities, the key areas that need to be optimized are determined.

[0050] S3. Obtain casting demand information, analyze casting demand information, and determine the expected flatness; The casting demand information may be the performance and appearance requirements that the casting needs to meet in the final application, such as mechanical properties, dimensional accuracy, appearance requirements, and use environment.

[0051] The desired flatness can be the desired flatness of the casting surface, which is usually related to the purpose and appearance requirements of the casting.

[0052] Specifically, in the simulation process, in addition to considering the shrinkage problem, it is also necessary to determine the expected casting quality based on the actual application requirements of the casting (such as strength, appearance, flatness, etc.). The expected flatness usually refers to the smoothness of the casting surface and the accuracy of the shape. Especially in castings that require high surface quality, shrinkage and deformation must be minimized. Determine the standard for the expected flatness based on the requirements of the casting. For example, the surface of the casting must achieve a certain degree of smoothness or deformation accuracy. By analyzing the flatness of the casting and combining the areas that may cause deformation in the simulation results, determine the optimization target of flatness.

[0053] S4. According to the shrinkage situation, the simulation parameters are adjusted, and step S2 is repeated according to the adjusted simulation parameters until the simulation results meet the expected flatness.

[0054] Specifically, the shrinkage predicted by the simulation results is combined with the expected casting quality standards (such as flatness) to dynamically adjust the simulation parameters until satisfactory simulation results are obtained. Based on the shrinkage determined by the simulation results, the causes of defects are identified and analyzed, such as factors such as too fast cooling rate or too high casting speed. These parameters are adjusted in a targeted manner to optimize the temperature control and metal flow path of the casting. The simulation is repeated by adjusting the simulation parameters (such as increasing the casting temperature, changing the cooling method, optimizing the gate position, etc.). After each simulation, the results are analyzed to see if shrinkage is reduced and flatness is improved. After adjusting the simulation parameters, the flatness and surface quality of the casting are checked to verify whether they meet the standards required in the casting demand information. If the simulation results still do not achieve the expected flatness, the parameters need to be adjusted again and the simulation process repeated.

[0055] Through this solution, according to the specific design of the casting (such as the location of the gate, riser, runner, etc.) and material properties, key simulation parameters (such as casting temperature, flow rate, cooling rate, etc.) are determined, providing a basis for subsequent simulation and optimization. Through in-depth analysis of casting planning information, problems that may affect casting quality can be discovered in advance. For example, dead corners may cause poor metal flow, thereby causing shrinkage holes, and these potential problems will be reflected in subsequent simulations. By analyzing the simulation results, possible shrinkage areas can be accurately identified. The simulation can provide the probability and location of shrinkage holes, providing a basis for the next step of optimization. The visualization of simulation results helps technicians understand the potential defects and temperature changes in the casting process more intuitively, thereby providing a clear reference for subsequent process adjustments. According to the actual use of the casting and customer needs, the quality standards of the casting in appearance and function are clarified. By analyzing the shrinkage situation (such as too fast cooling, too high casting speed, etc.), the simulation parameters are accurately adjusted. For example, appropriately increase the casting temperature, reduce the casting speed, or change the cooling method to optimize the temperature field distribution to ensure that there is no excessive temperature difference inside the casting, thereby effectively avoiding the formation of shrinkage cavities. Each adjusted simulation will give a new simulation result. Based on the new simulation results, technicians continue to analyze the defects of the castings, especially shrinkage cavities and surface quality, to ensure that these problems are effectively solved.

[0056] In some embodiments, the casting planning information is analyzed to determine the gate position, runner position and riser position; the casting information is obtained to determine the casting properties and casting structure; and the simulation parameters are determined based on the casting properties, casting structure, gate position, runner position and riser position.

[0057] Casting information can be all data related to casting production, such as geometry, material, quality requirements, performance requirements, surface quality, processing requirements, inspection standards, etc.

[0058] Casting properties can be the characteristics exhibited by castings under specific conditions. These characteristics are usually determined by the material, structure and manufacturing process of the castings, such as physical properties: density, melting point, thermal expansion coefficient, thermal conductivity, etc.; mechanical properties: strength, hardness, toughness, fatigue strength, etc.; chemical properties: corrosion resistance, oxidation resistance, chemical stability, etc.; heat treatment properties: weldability, heat treatability, castability, etc.

[0059] The structure of a casting can be the geometric shape of the casting, the internal structure and the relationship between its various parts, such as geometric features: such as the wall thickness, shape, size, etc. of the casting; internal structure: such as holes, ribs, supports, etc. inside the casting; connection method: such as the connection method of the various parts of the casting, such as welding, riveting, etc.; stress distribution: the stress distribution that may be generated during the casting and use of the casting; cooling method: the cooling rate and cooling method of the casting during the cooling process, such as water cooling, air cooling, etc.

[0060] Specifically, review the design drawings of the castings, including size, shape, wall thickness, connection parts, etc. Determine the location and size of the gates, runners and risers, which are the key channels for the flow of molten metal. Select appropriate casting materials, such as cast iron, cast steel, aluminum alloy, etc., according to the functional and performance requirements of the castings. Analyze the geometric shape and structural characteristics of the castings to determine possible stress concentration areas and thermal nodes. Analyze the physical and chemical properties of the selected materials, such as melting point, thermal conductivity, shrinkage, etc. Optimize the design of the gating system according to the geometric shape and structural characteristics of the castings to ensure the uniformity of the flow of molten metal and filling efficiency. Determine the appropriate casting temperature according to the material properties and the design of the gating system to ensure the fluidity and filling efficiency of the molten metal. Determine the appropriate casting speed according to the design of the gating system and the structural characteristics of the castings to avoid defects caused by too fast or too slow flow of molten metal. Select appropriate cooling methods, such as water cooling, air cooling, etc., according to the structure and material characteristics of the castings to control the cooling rate and shrinkage of the castings.

[0061] Through this solution, the location and size of the gate, runner and riser are determined. This information directly affects the flow of molten metal and the cooling process of the casting. Identify hot spots, thin walls and stress concentration areas in the casting structure, which are prone to defects such as shrinkage and cracks during the casting process. Determine the melting point, thermal conductivity, shrinkage rate and other properties of the selected material. These properties will affect the solidification process and final dimensional accuracy of the casting. The appropriate casting temperature can ensure that the molten metal has good fluidity and filling properties, reducing the formation of shrinkage and cracks. Controlling the casting speed can avoid the molten metal flowing too fast or too slow, thereby reducing defects such as under-casting and cold shut. Choosing the appropriate cooling method can control the cooling rate of the casting and reduce shrinkage and deformation.

[0062] In some embodiments, the casting partition is determined according to the casting structure; casting data is obtained according to the casting partition; the casting data is analyzed to determine the temperature change during the casting process; and special areas are determined according to the temperature change and the casting temperature.

[0063] Casting partitioning can be the process of dividing the casting into different areas for simulation and analysis according to the casting's geometric shape, structural characteristics and casting process requirements.

[0064] Casting data can be relevant parameters and data collected during the casting process, which are used to simulate and analyze the casting process of the casting.

[0065] Temperature change can refer to the change of the temperature of the casting and the molten metal over time during the casting process.

[0066] Special areas may be areas that require extra attention during the casting process as these areas may be high risk areas for defect formation, such as hot spots, thin walls, complex shapes, near gates, etc.

[0067] Specifically, the geometry of the casting is analyzed using CAD software or casting simulation software to identify areas with uneven wall thickness, complex shapes, or obvious heat nodes. Key structural features in the casting, such as supports, ribs, holes, etc., are identified, which have a significant effect on the flow and cooling of the molten metal. The casting is divided into several regions based on the geometry and structural features of the casting, each with similar thermal and flow characteristics. Based on the partitioning, the gating system is designed, including the location and size of the gate, runner, and riser. Basic parameters in the casting process, such as casting temperature, casting speed, and casting time, are determined. During the casting experiment or production process, actual casting data, such as the temperature, flow rate, and flow rate of the molten metal, are collected. Using casting simulation software, the temperature field during the casting process is simulated based on the casting data and the partitioning of the casting. The temperature gradient in the simulation results is analyzed to identify areas with drastic temperature changes, which may be high-risk areas for shrinkage cavity formation. The cooling rate of the casting in different regions is evaluated to determine the areas that may cause uneven cooling. Based on the temperature change and casting temperature, special areas that may cause shrinkage holes are identified, such as hot spots, thin-walled areas, etc. Risk assessment is performed on the identified special areas to determine which areas are most likely to form shrinkage holes. Optimization measures are proposed for special areas, such as adjusting the design of the gating system, changing the casting parameters, etc.

[0068] Through this solution, complex castings are decomposed into zones that are easier to manage and analyze. Through partitioning, the heat flow and solidification behavior of each zone can be simulated and analyzed more accurately, thus providing a basis for subsequent temperature change analysis and identification of special zones. Collect actual casting data related to each partition, such as casting temperature, casting speed, etc. These data are essential for simulating the flow and solidification process of molten metal, and help improve the accuracy and reliability of simulation. By analyzing the casting data, understand the temperature changes of the casting during the casting process. It helps to identify high-risk areas where shrinkage cavities may form and provide a basis for identifying special areas. Identify special areas where shrinkage cavities may form due to temperature changes and casting temperature. These areas may require special casting process adjustments or shrinkage compensation measures to reduce the formation of defects.

[0069] In some embodiments, structural changes in special areas are determined based on the structure of the casting; casting dead corners are determined based on the structural changes; dead corner casting speeds are determined based on the gate position and the runner position; initial casting speeds are determined based on the dead corner casting speeds, the gate position and the runner position; a casting cooling method is determined based on the structural changes; a casting temperature and a casting pressure are determined based on the initial casting speed and the casting cooling method; and the casting temperature, casting pressure and initial casting speed are determined as simulation parameters.

[0070] Structural changes can be changes in the internal or external morphology of the casting due to the flow, cooling and solidification of the molten metal during the casting process.

[0071] Casting dead corners can be areas that cannot be reached or filled by molten metal during the casting process due to obstructed or slow flow.

[0072] The dead corner casting speed can be that during the casting process, in order to fill the casting dead corner, the flow speed of the molten metal needs to be adjusted to a specific value.

[0073] The initial casting speed may be the initial flow speed of the molten metal at the start of casting.

[0074] The casting cooling method can be a method used to cool the casting to room temperature after casting.

[0075] Specifically, CAD software is used to analyze the geometric features of the castings and identify areas with uneven wall thickness, complex shapes or obvious hot spots. Determine the structural changes that may occur in the castings during the casting process, such as deformation, shrinkage, etc. According to the structural changes, the castings are divided into special areas, such as hot spots, thin walls, complex shapes, etc. Determine the areas where the molten metal is difficult to reach or flows slowly during the casting process. Use casting simulation software to analyze the flow path of the molten metal and identify potential casting dead corners. Confirm the location and range of the casting dead corners through simulation results and actual production experience. Design the layout of the gates and runners based on the structure of the castings and the location of the casting dead corners. Calculate the casting speed in the dead corner area based on the size of the gates and runners and the fluidity of the molten metal. Ensure that the initial casting speed can meet the requirements of the gating system design while avoiding defects in the casting dead corners. Adjust the initial casting speed based on the simulation results and actual experience to optimize the flow of the molten metal. Select the appropriate cooling method based on the structural changes and material properties of the castings. Determine the parameters such as the temperature and flow rate of the cooling medium, as well as the control strategy during the cooling process. According to the characteristics of metal materials, casting speed and cooling method, the casting temperature and casting pressure are calculated. Through simulation and experiments, the casting temperature and pressure are optimized to reduce the formation of defects. According to the above analysis and optimization results, the final simulation parameters are determined, including casting temperature, casting pressure and initial casting speed.

[0076] Through this solution, special areas in the casting, such as hot spots, thin walls, complex shapes, etc., are identified, and the structural changes of these areas during the casting process are analyzed. This helps to predict the casting defects that may occur in these areas, such as shrinkage cavities, cracks, etc. The casting speed of the dead corner area is determined according to the design of the gate and runner. The appropriate casting speed helps the molten metal to fully fill the dead corner and reduce defects. According to the casting speed of the dead corner and other related factors, the initial casting speed of the entire casting is determined. This is the key to ensure that the molten metal flows evenly throughout the mold. According to the structural changes and material properties of the casting, the appropriate cooling method is selected. The choice of cooling method has an important impact on the stress and deformation of the casting. According to the initial casting speed and the cooling method of the casting, the casting temperature and pressure are determined. These parameters have a direct impact on the fluidity of the molten metal and the solidification process of the casting. The above-determined parameters are used as simulation parameters for the simulation of the casting process. These parameters will directly affect the accuracy of the simulation and the prediction of defects.

[0077] In some embodiments, according to the structural changes, the casting structure is simulated and disassembled into cells to obtain casting units; according to the shrinkage situation, the defect location is determined, and the shrinkage situation is analyzed to determine the shrinkage size and actual temperature change of each defect location; according to the defect location, the associated location is determined; according to the associated location and the defect location, the adjustment area is determined; according to the shrinkage size and the actual temperature change, the expected temperature for solving the shrinkage at the defect location is determined; according to the expected temperature, the simulation parameters are adjusted.

[0078] Cellular simulation disassembly can be a way to break down complex casting structures into smaller, more easily analyzed parts.

[0079] Casting units can be small casting parts obtained in a cell simulation disassembly process.

[0080] The defect location may be the location in the casting where the defect occurs.

[0081] The shrinkage cavity size can be the volume or diameter of the shrinkage cavity.

[0082] The actual temperature change may be the change in the casting temperature during the casting process.

[0083] The associated positions may be other positions that are directly related to the defect position.

[0084] The adjustment area may be an area where parameter adjustment is required to solve a defect problem.

[0085] Specifically, simulation software is used to divide the casting into multiple cells, each of which represents a small area of ​​the casting. Each cell is simulated independently to analyze its heat flow and solidification behavior. Shrinkage defects in the casting are identified through simulation results or actual detection methods. The location, size and surrounding temperature distribution of each shrinkage cavity are analyzed. The heat flow and stress distribution around the defect location are analyzed to determine the associated locations that may affect the formation of defects. The defect location and associated locations are comprehensively considered to determine the specific areas that need to be adjusted. According to the size of the shrinkage cavity and the actual temperature change, a desired temperature range is set to solve the shrinkage cavity problem. According to the desired temperature, the simulation parameters are adjusted, such as increasing or decreasing the casting temperature, changing the casting speed, adjusting the cooling method, etc.

[0086] Through this solution, complex casting structures are broken down into smaller, more manageable units. These units can be simulated independently, which helps to more accurately analyze the local behavior of the casting, such as hot spots, shrinkage holes, etc. Identify the location of shrinkage defects in the casting and analyze the specific conditions of these defects. By determining the size of the shrinkage holes and the actual temperature change, it can provide a basis for subsequent defect resolution. Identify other locations related to the defect location that may affect or be affected by the defect. The determination of associated locations helps to fully understand the cause of the defect. Determine specific areas that need to be adjusted in order to resolve the shrinkage defect. The adjustment area may include the defect location itself and the locations associated with it. Based on the size of the shrinkage hole and the actual temperature change, determine a desired temperature range to resolve the shrinkage problem. This temperature range will be used to guide the adjustment of simulation parameters. Based on the determined desired temperature, adjust simulation parameters such as casting temperature, casting speed, cooling method, etc. to achieve the purpose of resolving shrinkage holes.

[0087] In some embodiments, the gate diameter is determined according to the gate position; based on the gate diameter, the casting structure is analyzed to determine the gate adjustment position; the casting position is determined according to the casting temperature, the initial casting speed and the expected temperature; the gate position adjustment plan is determined according to the casting position and the gate adjustment position; and the simulation parameters are adjusted according to the gate position adjustment plan.

[0088] The gate diameter can be the size of the gate (the channel used to introduce molten metal into the mold).

[0089] The gate adjustment position can be determined in the casting structure, based on the position of the gate and the geometry of the casting, to determine the position where the gate may need to be adjusted.

[0090] The pouring position may be the position where the molten metal enters the mold during the casting process.

[0091] The gate position adjustment scheme may be a scheme for adjusting the gate position during the casting process in order to optimize the flow path of the molten metal and reduce the formation of defects.

[0092] Specifically, analyze the effect of gate diameter on the flow of molten metal, determine the appropriate gate diameter, and ensure that the molten metal can evenly fill the mold. Use casting simulation software to simulate the flow path of molten metal in the mold and analyze the effect of gate diameter on flow. According to the analysis results, determine the size and shape of the gate diameter. Analyze the effect of gate diameter on the structure of the casting and determine the position where the gate may need to be adjusted. According to the analysis results, determine the position where the gate may need to be adjusted. Use casting simulation software to simulate the casting process, analyze the effect of casting temperature, initial casting speed and expected temperature on the flow and solidification of molten metal, and analyze the optimal casting position of molten metal. According to the simulation results, determine the optimal casting position of molten metal to ensure that the molten metal can evenly fill the mold. Analyze the effect of casting position and gate adjustment position on the flow and solidification of molten metal, analyze the adjustment plan of gate position, and determine the best gate position adjustment plan, including gate position movement, size adjustment, etc. According to the gate position adjustment plan, analyze the adjustment plan of simulation parameters. According to the analysis results, determine the adjustment plan of simulation parameters.

[0093] Through this solution, the appropriate gate diameter is determined according to the location of the gate and the geometry of the casting. The size of the gate diameter affects the flow rate and flow of the molten metal, which in turn affects the filling and solidification process of the casting. Analyze the effect of the gate diameter on the structure of the casting, and determine the location where the gate may need to be adjusted based on the analysis results. This helps to optimize the gating system and reduce the formation of defects. Determine the best casting position of the molten metal based on the casting temperature, initial casting speed and expected temperature. This helps to ensure that the molten metal can fill the mold evenly and reduce the formation of defects. Determine the adjustment plan for the gate position based on the casting position and the location where the gate may need to be adjusted. This helps to optimize the gating system and improve the quality of the casting. According to the adjustment plan for the gate position, adjust the simulation parameters such as casting temperature, casting speed, cooling method, etc. This helps to improve the accuracy of the simulation and the quality of the casting.

[0094] In some embodiments, based on the gate diameter, the casting structure is analyzed to determine a suitable position that meets the gate diameter; the surrounding structure of the suitable position is analyzed to determine the grinding difficulty; based on the grinding difficulty, it is determined whether to use the suitable position as the gate adjustment position.

[0095] The suitable position may be a location in the casting structure suitable for placing the gate, determined based on the gate diameter and the design requirements of the casting.

[0096] The surrounding structure can be the casting structure around the appropriate position, including wall thickness, shape, reinforcement ribs, hot spots, etc.

[0097] Grinding difficulty can be the difficulty coefficient when grinding the casting, which depends on the surrounding structure of the casting and the use of grinding tools.

[0098] Specifically, casting simulation software is used to simulate the flow path of molten metal in the mold and analyze the effect of gate diameter on flow. According to the structure and size of the casting, select the appropriate gate diameter to ensure the stability and efficiency of the molten metal flow. Consider the structural characteristics of the casting, such as wall thickness, shape, thermal joints, etc., to determine whether the gate needs to be adjusted. According to the structure and size of the casting, select a suitable gate position to ensure that the molten metal can evenly fill the mold. Analyze the surrounding structures of the appropriate position, such as wall thickness, shape, thermal joints, etc., to determine whether the gate needs to be adjusted. According to the surrounding structures of the appropriate position, evaluate the difficulty of grinding to determine whether the gate needs to be adjusted. Based on the evaluation results, determine whether to use the appropriate position as the gate adjustment position.

[0099] Through this solution, ensure that the location of the gate can meet the requirements of the gate diameter, while taking into account the structural characteristics of the casting, such as wall thickness, shape and thermal joints. This helps to avoid uneven metal flow or defect formation caused by improper gate location. Evaluate the impact of the casting structure around the gate on the grinding process and the difficulty of grinding. This helps to improve efficiency and quality in the subsequent manufacturing process. Decide whether the gate position needs to be adjusted based on the difficulty of grinding to ensure the quality of the casting and the efficiency of production.

[0100] In some embodiments, the cooling point position is determined according to the shrinkage situation; the riser adjustment plan is determined according to the gate position and the cooling point position; and the simulation parameters are adjusted according to the gate position adjustment plan and the riser adjustment plan.

[0101] The cooling point location may be the specific location in the casting where the molten metal last cools.

[0102] The riser adjustment plan can be to optimize the filling and solidification process of the casting, such as increasing the number of risers, changing the shape of the risers, adjusting the position of the risers, etc.

[0103] Specifically, casting simulation software, such as ProCAST or MAGMA, is used to perform simulation analysis and identify the location of shrinkage cavities. According to the location of shrinkage cavities, cooling points are set. In the casting, the specific location of shrinkage cavities formed due to the cooling of the molten metal at the cooling points. Considering the location of the gate and cooling points, the size and shape of the riser, as well as the connection method of the riser, are designed. The impact of the riser adjustment plan on the quality of the casting and the production cost is evaluated. According to the riser adjustment plan, the parameters such as casting temperature, casting speed and cooling method are adjusted.

[0104] Through this solution, shrinkage cavities in castings are analyzed and the location of cooling points is determined so that shrinkage defects can be reduced or eliminated by controlling cooling. According to the location of gates and cooling points, the design of risers is adjusted to ensure that the molten metal can fully fill the mold and reduce defects. According to the adjustment plan of gates and risers, the simulation parameters are adjusted to optimize the quality of castings.

[0105] In some embodiments, the actual heating condition of the defect location is determined based on the casting speed and the initial casting temperature; the expected heat for achieving the expected flatness under the influence of the casting properties is determined based on the expected flatness and the casting properties; the influence range of the defect location is determined based on the temperature change and the expected heat; and the associated location is determined based on the influence range.

[0106] The actual heating conditions may be the actual temperature changes and heat distribution experienced by the casting during the casting process.

[0107] The desired heat may be the desired internal temperature of the casting in order to achieve a specific casting quality standard, such as flatness, strength, etc.

[0108] The affected area can be the thermal influence range of the defect location in the casting on its surrounding area.

[0109] Specifically, casting simulation software, such as ProCAST or MAGMA, is used to simulate the casting process and analyze the actual heating conditions at the defect location. Through heat flow simulation, the flow and heat transfer of molten metal in the mold can be understood. The flatness requirements of the casting are analyzed to determine the temperature conditions for achieving the desired flatness. Consider the effects of the casting's material, wall thickness, shape and other properties on the temperature distribution. By analyzing the temperature gradient, the heat transfer area around the defect location is determined. Based on the temperature change and the expected heat, the influence range of the defect location is determined to provide a basis for subsequent optimization. By analyzing the influence range, the casting area directly associated with the defect location is identified.

[0110] Through this solution, the actual heating conditions of the defect location during the casting process are understood, providing a basis for subsequent temperature control and defect prevention. Determine the expected heat that the casting should reach during the cooling process in order to achieve the desired casting flatness. Determine the temperature influence range around the defect location so that appropriate measures can be taken. Analyze the temperature gradient around the defect location and determine the affected heat transfer area. Determine the influence range of the defect location based on the temperature change and the expected heat. Based on the influence range of the defect location, determine the associated position so that the optimization of the casting can be considered as a whole.

[0111] Figure 3 A schematic diagram of a casting shrinkage defect prediction system based on virtual simulation technology is provided in one embodiment of the present application. Figure 3As shown, the casting shrinkage defect prediction system 300 based on virtual simulation technology of this embodiment includes: an information analysis module 301 , a shrinkage determination module 302 , a demand analysis module 303 , and an adjustment module 304 .

[0112] An information analysis module 301 is used to obtain casting planning information, analyze the casting planning information, and determine simulation parameters; The shrinkage cavity determination module 302 is used to perform simulation according to the simulation parameters to obtain simulation results, and determine the shrinkage cavity situation according to the simulation results; The demand analysis module 303 is used to obtain casting demand information, analyze the casting demand information, and determine the expected flatness; The adjustment module 304 is used to adjust the simulation parameters according to the shrinkage situation, and repeatedly execute the shrinkage determination module according to the adjusted simulation parameters until the simulation result meets the expected flatness.

[0113] Optionally, when the information analysis module 301 analyzes the casting planning information and determines simulation parameters, it is used to: Analyze the casting planning information to determine the gate position, runner position and riser position; Obtain casting information and determine casting properties and casting structure; The simulation parameters are determined according to the casting properties, the casting structure, the gate position, the runner position and the riser position.

[0114] Optionally, the simulation parameters include casting temperature, and the casting shrinkage defect prediction system 300 further includes a regional analysis module 305 for: Determine the casting partitioning conditions according to the casting structure; Acquiring casting data according to the casting partitioning conditions; Analyzing the casting data to determine temperature changes during the casting process; A special area is determined based on the temperature change and the casting temperature.

[0115] Optionally, when the information analysis module 301 determines the simulation parameters according to the casting properties, the casting structure, the gate position, the runner position and the riser position, it is used to: Determining structural changes in the special area according to the casting structure; Determine the casting dead angle according to the structural changes; Determining a dead corner casting speed of the casting dead corner according to the gate position and the runner position; Determining an initial casting speed according to the dead angle casting speed, the gate position and the runner position; Determining a casting cooling method according to the structural changes; Determining the casting temperature and casting pressure according to the initial casting speed and the casting cooling method; The casting temperature, the casting pressure and the initial casting speed are determined as the simulation parameters.

[0116] Optionally, when the adjustment module 304 adjusts the simulation parameters according to the shrinkage situation, it is used to: According to the structural changes, the casting structure is subjected to a cell-by-cell simulation disassembly to obtain a casting unit; Determine the defect location according to the shrinkage cavity situation, and analyze the shrinkage cavity situation to determine the shrinkage cavity size and actual temperature change of each defect location; Determining a related position according to the defect position; Determining an adjustment area according to the associated position and the defect position; Determining the expected temperature for resolving the shrinkage cavity at the defect location according to the shrinkage cavity size and the actual temperature change; The simulation parameters are adjusted according to the expected temperature.

[0117] Optionally, when the adjustment module 304 adjusts the simulation parameter according to the expected temperature, it is used to: According to the gate position, determine the gate diameter; Based on the gate diameter, analyzing the casting structure, and determining the gate adjustment position; Determining a casting position according to the casting temperature, the initial casting speed and the expected temperature; Determining a gate position adjustment plan according to the casting position and the gate adjustment position; The simulation parameters are adjusted according to the gate position adjustment scheme.

[0118] Optionally, when the adjustment module 304 analyzes the casting structure based on the gate diameter and determines the gate adjustment position, it is used to: Based on the gate diameter, analyzing the casting structure, determining a suitable position that satisfies the gate diameter; Analyze the surrounding structures of the suitable location to determine the difficulty of grinding; According to the grinding difficulty, it is determined whether to use the appropriate position as the gate adjustment position.

[0119] Optionally, when the adjustment module 304 adjusts the simulation parameters according to the gate position adjustment scheme, it is used to: According to the shrinkage cavity situation, determine the cooling point position; Determine a riser adjustment plan according to the gate position and the cooling point position; The simulation parameters are adjusted according to the gate position adjustment scheme and the riser adjustment scheme.

[0120] Optionally, when determining the associated position according to the defect position, the adjustment module 304 is used to: Determining actual heating conditions of the defect location according to the casting speed and the initial casting temperature; Determining, according to the desired flatness and the properties of the casting, a desired heat for achieving the desired flatness under the influence of the properties of the casting; Determining the impact range of the defect position according to the temperature change and the expected heat; According to the impact range, an associated position is determined.

[0121] 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 shrinkage defect prediction method based on virtual simulation technology, characterized in that: include: S1. Obtain casting planning information, analyze the casting planning information, and determine simulation parameters; S2. Performing simulation according to the simulation parameters to obtain simulation results, and determining shrinkage conditions according to the simulation results; S3. Obtain casting demand information, analyze the casting demand information, and determine the desired flatness; S4. According to the shrinkage situation, the simulation parameters are adjusted, and according to the adjusted simulation parameters, step S2 is repeated until the simulation results meet the desired flatness.

2. The method according to claim 1, characterized in that The step of analyzing the casting planning information and determining simulation parameters includes: Analyze the casting planning information to determine the gate position, runner position and riser position; Obtain casting information and determine casting properties and casting structure; The simulation parameters are determined according to the casting properties, the casting structure, the gate position, the runner position and the riser position.

3. The method according to claim 2, characterized in that The simulation parameters include casting temperature. Before determining the shrinkage situation according to the simulation results, the method further includes: Determine the casting partitioning conditions according to the casting structure; Acquiring casting data according to the casting partitioning conditions; Analyzing the casting data to determine temperature changes during the casting process; A special area is determined based on the temperature change and the casting temperature.

4. The method according to claim 3, characterized in that Determining simulation parameters according to the casting properties, the casting structure, the gate position, the runner position and the riser position includes: Determining structural changes in the special area according to the casting structure; Determine the casting dead angle according to the structural changes; Determining a dead corner casting speed of the casting dead corner according to the gate position and the runner position; Determining an initial casting speed according to the dead angle casting speed, the gate position and the runner position; Determining a casting cooling method according to the structural changes; Determining the casting temperature and casting pressure according to the initial casting speed and the casting cooling method; The casting temperature, the casting pressure and the initial casting speed are determined as the simulation parameters.

5. The method according to claim 4, characterized in that The step of adjusting the simulation parameters according to the shrinkage conditions includes: According to the structural changes, the casting structure is subjected to a cell-by-cell simulation disassembly to obtain a casting unit; Determine the defect location according to the shrinkage cavity situation, and analyze the shrinkage cavity situation to determine the shrinkage cavity size and actual temperature change of each defect location; Determining a related position according to the defect position; Determining an adjustment area according to the associated position and the defect position; Determining the expected temperature for resolving the shrinkage cavity at the defect location according to the shrinkage cavity size and the actual temperature change; The simulation parameters are adjusted according to the expected temperature.

6. The method according to claim 5, characterized in that The adjusting the simulation parameters according to the expected temperature includes: According to the gate position, determine the gate diameter; Based on the gate diameter, analyzing the casting structure, and determining the gate adjustment position; Determining a casting position according to the casting temperature, the initial casting speed and the expected temperature; Determining a gate position adjustment plan according to the casting position and the gate adjustment position; The simulation parameters are adjusted according to the gate position adjustment scheme.

7. The method according to claim 6, characterized in that The step of analyzing the casting structure based on the gate diameter and determining the gate adjustment position includes: Based on the gate diameter, analyzing the casting structure, determining a suitable position that satisfies the gate diameter; Analyze the surrounding structures of the suitable location to determine the difficulty of grinding; According to the grinding difficulty, it is determined whether to use the appropriate position as the gate adjustment position.

8. The method according to claim 6, characterized in that The step of adjusting the simulation parameters according to the gate position adjustment scheme includes: According to the shrinkage cavity situation, determine the cooling point position; Determine a riser adjustment plan according to the gate position and the cooling point position; The simulation parameters are adjusted according to the gate position adjustment scheme and the riser adjustment scheme.

9. The method according to claim 5, characterized in that The determining of the associated position according to the defect position includes: Determining actual heating conditions of the defect location according to the casting temperature and the initial casting speed; Determining, according to the desired flatness and the properties of the casting, a desired heat for achieving the desired flatness under the influence of the properties of the casting; Determining the impact range of the defect position according to the temperature change and the expected heat; According to the impact range, an associated position is determined.

10. A casting shrinkage defect prediction system based on virtual simulation technology, characterized in that: include: An information analysis module, used to obtain casting planning information, analyze the casting planning information, and determine simulation parameters; A shrinkage cavity determination module is used to perform simulation according to the simulation parameters to obtain simulation results, and determine the shrinkage cavity situation according to the simulation results; A demand analysis module, used to obtain casting demand information, analyze the casting demand information, and determine the expected flatness; The adjustment module is used to adjust the simulation parameters according to the shrinkage situation, and repeatedly execute the shrinkage determination module according to the adjusted simulation parameters until the simulation result meets the expected flatness.

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