A casting quality control method and system based on Magmasoft

Abstract

The present application relates to the field of casting control technology, and in particular to a casting quality control method and system based on Magmasoft. The method includes: obtaining a mold data set and a casting parameter set, simulating a vacuum casting process based on the mold data set and the casting parameter set, and determining the simulation results; analyzing the mold data set, screening the simulation results, and determining the key impact data set of the seal; obtaining the seal parameter set, analyzing the key impact data set of the seal based on the seal parameter set, and determining the potential risk information of the seal; determining and outputting the risk report and suggestion information based on the potential risk information of the seal. The present application realizes the scientific analysis of the potential risks of mold seals in the vacuum casting process, so that the potential risks of the seals can be discovered and reduced in time, thereby improving the quality and pass rate of the final castings.

Description

Technical Field

[0001] The present application relates to the field of casting control technology, and in particular to a casting quality control method and system based on Magmasoft. Background Art

[0002] In today's foundry industry, vacuum casting is an efficient and high-quality casting method widely used in the automotive, aerospace, electronics and other fields. Because it can significantly improve the density and strength of castings, the quality and pass rate of finished products have attracted much attention. During the vacuum casting process, the state of the mold seal is crucial to the quality of the casting and directly affects the maintenance of the vacuum environment inside the mold during the vacuum casting process.

[0003] However, existing vacuum casting quality control technologies usually only focus on simulating the state changes of the casting itself during the casting process. It is difficult to accurately analyze the impact of casting state changes on mold seals, resulting in potential risks of mold seals being difficult to detect in a timely manner, which in turn has a negative impact on the final casting quality. Summary of the invention

[0004] The present application provides a casting quality control method and system based on Magmasoft to solve the above technical problems.

[0005] In a first aspect, the present application provides a casting quality control method based on Magmasoft, the method comprising:

[0006] Acquire a mold data set and a casting parameter set, simulate a vacuum casting process according to the mold data set and the casting parameter set, and determine a simulation result;

[0007] Analyze the mold data set, screen the simulation results, and determine a key impact data set of the seal;

[0008] Acquire a seal parameter set, and based on the seal parameter set, analyze the seal key impact data set to determine the seal potential risk information;

[0009] Based on the potential risk information of seals, determine and output risk reports and recommendation information.

[0010] Through this scheme, the vacuum casting process is simulated according to the mold data set and the casting parameter set to obtain the simulation results, and on this basis, the simulation results are screened according to the mold data set to determine the key influencing data set of seals that will have a direct impact on the mold seals in the vacuum casting process in the simulation results, and based on this, combined with the seal parameter set, the potential risks of seals in the vacuum casting process are analyzed to obtain the potential risk information of seals, and based on the potential risk information of seals, risk reports and recommendation information are generated and output for casting operators to intuitively understand the status of seals and the direction of reducing potential risks of seals, thereby realizing a scientific analysis of the potential risks of mold seals in the vacuum casting process, so that the potential risks of seals can be discovered and reduced in time, thereby improving the quality and pass rate of the final castings.

[0011] Optionally, simulating the vacuum casting process according to the mold data set and the casting parameter set to determine the simulation result includes:

[0012] Importing the mold data set into Magmasoft, determining the mold three-dimensional model, and defining the mold material data corresponding to the mold three-dimensional model according to the casting parameter set;

[0013] According to the casting parameter set, vacuum system parameters, casting conditions and casting materials are defined;

[0014] Receiving a flow rate simulation data set, a temperature simulation data set, a pressure simulation data set and a stress simulation data set simulated by Magmasoft based on the mold three-dimensional model and the mold material data, according to the vacuum system parameters, the casting conditions and the casting material;

[0015] The flow velocity simulation data set, the temperature simulation data set, the pressure simulation data set and the stress simulation data set are taken as the simulation results.

[0016] Through this solution, Magmasoft is used to create, define and set the mold 3D model, mold material data, vacuum system parameters, casting conditions and casting materials required for the vacuum casting simulation process according to the mold data set and casting parameter set. On this basis, the vacuum casting process is simulated to obtain the flow rate simulation data set, temperature simulation data set, pressure simulation data set and stress simulation data set. The above series of data sets are used as simulation results to provide scientific data basis for the subsequent potential risk analysis process of seals.

[0017] Optionally, analyzing the mold data set, screening the simulation results, and determining a seal key influencing data set includes:

[0018] Extracting a seal contact surface in the mold according to the mold data set;

[0019] According to a preset division rule, a plurality of analysis points are set in the mold model geometry structure corresponding to the mold data set, and a relative distance between each of the analysis points and the seal contact surface is extracted;

[0020] Analyze the simulation results according to the plurality of analysis points, and extract the fluid velocity value, temperature value, pressure value and stress value corresponding to each analysis point;

[0021] According to the mold material data, determining the lower limit of flow velocity influence, the lower limit of pressure influence, the lower limit of temperature influence and the lower limit of stress influence;

[0022] Based on the seal contact surface, the mold model and the relative distance, and according to the flow velocity influence lower limit, the pressure influence lower limit, the temperature influence lower limit and the stress influence lower limit, the fluid flow velocity value, the temperature value, the pressure value and the stress value corresponding to each analysis point are analyzed to determine a set of key analysis points;

[0023] A seal key influencing data set is determined according to simulation data corresponding to the key analysis point set in the simulation result.

[0024] Through this solution, based on the mold data set, the seal contact surface that is in direct contact between the mold and the seal is extracted. Based on this, the relative distances between the different analysis points obtained and the seal contact surface are extracted. At the same time, based on the mold material data, the flow velocity influence lower limit, pressure influence lower limit, temperature influence lower limit and stress influence lower limit corresponding to each type of data in the simulation results are determined. Based on this, the fluid flow velocity value, temperature value, pressure value and stress value corresponding to each analysis point are analyzed to obtain a set of key analysis points, and the seal key influence data set is constructed based on this, which effectively focuses the analysis on the key area around the seal, while reducing the interference of irrelevant data, enhancing the pertinence and efficiency of subsequent potential risk analysis of the seal, and significantly reducing the calculation complexity while ensuring data accuracy.

[0025] Optionally, based on the seal contact surface, the mold model and the relative distance, according to the flow velocity influence lower limit, the pressure influence lower limit, the temperature influence lower limit and the stress influence lower limit, the fluid flow velocity value, the temperature value, the pressure value and the stress value corresponding to each analysis point are analyzed to determine a set of key analysis points, specifically the following formula:

[0026] R ={ I ∈ M}∨{ I ∈ Oh ∧ d I <D | V I ≥ V n ∨ P I ≥ P n ∨ T I ≥ T n ∨ s I ≥ s n};

[0027] in, R is the key analysis point set, I is the current analysis point, M is the seal contact surface, Oh is the mold model geometry, d I is the relative distance between the current analysis point and the contact surface of the seal, D is the preset distance threshold, V I is the fluid velocity value corresponding to the current analysis point, V n is the lower limit of the flow velocity, P I is the pressure value corresponding to the current analysis point, P n is the lower limit of the pressure influence, T I is the temperature value corresponding to the current analysis point, T n is the lower limit of the temperature influence, s I is the stress value corresponding to the current analysis point, s n is the lower limit of the stress influence.

[0028] Through this solution, mathematical analysis methods are used, based on the seal contact surface, mold model and relative distance, according to the lower limits of flow rate influence, pressure influence, temperature influence and stress influence, and scientific restrictions are placed on the requirements of the key analysis points in the key analysis point set through clear mathematical language. Combined with the fluid flow rate value, temperature value, pressure value and stress value corresponding to each analysis point, automatic batch screening of simulation results is achieved, and a highly refined set of key analysis points required for the subsequent potential analysis process of the seal is obtained. Data redundancy is significantly reduced by removing irrelevant data and refining valid data.

[0029] Optionally, the seal parameter set includes material tensile strength and thermal expansion coefficient, and the step of analyzing the seal key impact data set based on the seal parameter set to determine the seal potential risk information includes:

[0030] Determining a material characteristic factor according to the material tensile strength and the thermal expansion coefficient;

[0031] According to the seal key impact data set, the fluid flow rate values, the temperature values, the pressure values ​​and the stress values ​​corresponding to all key analysis points are sorted in ascending order, and according to the sorting results, a high quantile flow rate value, a high quantile temperature value, a high quantile pressure value and a high quantile stress value are determined;

[0032] Determining an external comprehensive influencing factor according to the high quantile flow velocity value, the high quantile temperature value, the high quantile pressure value and the high quantile stress value;

[0033] The material characteristic factors and the external comprehensive influencing factors are analyzed to determine a comprehensive potential risk value, and the comprehensive potential risk value, the material characteristic factors and the external comprehensive influencing factors are determined as the potential risk information of the seal.

[0034] Through this scheme, according to the tensile strength and thermal expansion coefficient of the material, the material characteristic factors that can reflect the impact of the material characteristics of the seal on the potential risks are analyzed and determined. At the same time, the high percentile flow rate value, high percentile temperature value, high percentile pressure value and high percentile stress value are determined by selecting high percentile values ​​to ensure the representativeness of the data. On this basis, the external comprehensive influencing factors that can reflect the comprehensive impact of external influencing factors on the potential risks of the seal are analyzed and obtained. Through the combined analysis of the material characteristic factors and the external comprehensive influencing factors, the comprehensive potential risk value of the seal under the above-mentioned dual influences is obtained, and the comprehensive potential risk value, material characteristic factors and external comprehensive influencing factors are determined as the potential risk information of the seal, thereby improving the accuracy and comprehensiveness of the potential risks of the seal.

[0035] Optionally, the material characteristic factor and the external comprehensive influencing factor are analyzed to determine a comprehensive potential risk value, specifically the following formula:

[0036] ;

[0037] in, G is the comprehensive potential risk value, A is the preset strength relationship coefficient, B To preset the intensity influence adjustment index, S is the tensile strength of the material, f is the preset temperature response index, L is the preset temperature influence coefficient, Eis the thermal expansion coefficient, is the material characteristic factor, H is the external comprehensive influencing factor.

[0038] Through this scheme, mathematical analysis is used to describe the nonlinear effects of material tensile strength and thermal expansion coefficient on the potential risks of seals, so as to quantify material characteristic factors. Combined with external comprehensive influencing factors, scientific quantification of the comprehensive potential risk value is achieved, thereby improving the accuracy and comprehensiveness of the comprehensive potential risk value analysis process.

[0039] Optionally, the external comprehensive influencing factor is determined according to the high quantile flow rate value, the high quantile temperature value, the high quantile pressure value and the high quantile stress value, specifically as the following formula:

[0040] ;

[0041] in, V is the high percentile flow rate value, α is the preset velocity influence condition coefficient, β The preset temperature affects the adjustment index. T is the high quantile temperature value, T 0 is the preset reference temperature value, P is the high percentile pressure value, C is the preset pressure threshold, s is the high quantile stress value, s 0 is the default stress reference.

[0042] Through this scheme, mathematical analysis is used to describe the nonlinear effects of flow, temperature, pressure and stress on the potential risks of seals based on high quantile flow velocity values, high quantile temperature values, high quantile pressure values ​​and high quantile stress values ​​through clear mathematical relationships, so as to quantify the external comprehensive influencing factors, thereby ensuring the scientificity and comprehensiveness of the external comprehensive influencing factors.

[0043] Optionally, determining and outputting risk report and suggestion information based on the potential risk information of the seal includes:

[0044] Comparing the comprehensive potential risk value in the potential risk information with a preset risk threshold to determine whether the comprehensive potential risk value exceeds the preset risk threshold;

[0045] If the comprehensive potential risk value exceeds the preset risk threshold, analyzing and determining the influence ratio of the material characteristic factor and the external comprehensive influencing factor on the comprehensive potential risk value;

[0046] If the influence ratio of the material characteristic factor is greater than the influence ratio of the external comprehensive influencing factor, the seal material re-evaluation requirement is output as the recommendation information;

[0047] If the influence ratio of the external comprehensive influencing factors is greater than the influence ratio of the material characteristic factors, the casting process re-evaluation requirement is output as the suggestion information;

[0048] The risk report is constructed and output based on the potential risk information, the impact ratio of the material characteristic factors and the impact ratio of the external comprehensive influencing factors.

[0049] Through this solution, at the stage of outputting risk reports and recommendation information, by comparing the influence ratios of material characteristic factors and external comprehensive influencing factors, the decisive factors affecting the potential risks of seals are further located, so as to determine the corresponding recommendation information, so that the casting operators who receive the recommendation information can clarify the subsequent improvement direction, so as to indirectly improve the quality of castings.

[0050] Optionally, the method further includes:

[0051] Based on the mold data set, according to the vacuum system parameters, the casting conditions and the casting materials, evaluating the mold flying risk and the corresponding flying high-risk area in the demolding stage;

[0052] The mold flying material risk is compared with a preset flying material risk threshold. If the mold flying material risk exceeds the preset flying material risk threshold, the mold flying material risk is included in the risk report, and the flying material high-risk area is focused on and included in the recommendation information.

[0053] Through this plan, the mold flying material risk and the corresponding high-risk areas of flying material during the demolding stage of the vacuum casting process are analyzed and determined to clarify whether the current mold flying material risk will affect the quality of the casting. At the same time, the differentiated impact of flying material on castings and molds is clarified, so that the corresponding personnel can further optimize the vacuum casting process according to the mold flying material situation, thereby further improving the quality of castings.

[0054] In a second aspect, the present application provides a casting quality control system based on Magmasoft, the system comprising:

[0055] A casting simulation module, used for acquiring a mold data set and a casting parameter set, simulating a vacuum casting process according to the mold data set and the casting parameter set, and determining a simulation result;

[0056] A data screening module, used for analyzing the mold data set, screening the simulation results, and determining a key impact data set of the seal;

[0057] A risk analysis module, used for acquiring a seal parameter set, analyzing the seal key impact data set based on the seal parameter set, and determining potential risk information of the seal;

[0058] The output module is used to determine and output risk reports and suggestion information based on the potential risk information of the seals. BRIEF DESCRIPTION OF THE DRAWINGS

[0059] 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.

[0060] Figure 1 A schematic diagram of an application scenario provided for an embodiment of the present application;

[0061] Figure 2 A flowchart of a casting quality control method based on Magmasoft provided in one embodiment of the present application;

[0062] Figure 3 A schematic structural diagram of a casting quality control system based on Magmasoft provided in one embodiment of the present application. DETAILED DESCRIPTION

[0063] 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.

[0064] 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.

[0065] The embodiments of the present application are further described in detail below in conjunction with the drawings in the specification.

[0066] Existing vacuum casting quality control technology usually only focuses on simulating the state changes of the casting itself during the casting process. It is difficult to accurately analyze the impact of casting state changes on mold seals, resulting in potential risks of mold seals being difficult to detect in a timely manner, which in turn has a negative impact on the final casting quality.

[0067] Based on this, the present application provides a casting quality control method and system based on Magmasoft. According to the mold data set and the casting parameter set, the vacuum casting process is simulated to obtain the simulation results, and on this basis, according to the mold data set, the simulation results are screened to determine the key impact data set of the seals that will have a direct impact on the mold seals in the vacuum casting process within the simulation results, and based on this, combined with the seal parameter set, the potential risks of the seals in the vacuum casting process are analyzed to obtain the potential risk information of the seals, and based on the potential risk information of the seals, risk reports and suggestion information are generated and output, so that the casting operators can intuitively understand the state of the seals and the direction of reducing the potential risks of the seals, and realize the scientific analysis of the potential risks of the mold seals in the vacuum casting process, so that the potential risks of the seals can be discovered and reduced in time, thereby improving the quality and qualified rate of the final castings.

[0068] Figure 1 A schematic diagram of an application scenario provided by the present application. In the vacuum casting process, the method provided by the present application is applied to achieve a scientific analysis of the potential risks of mold seals in the vacuum casting process to improve the quality of castings.

[0069] Specifically, the method of the present application is applied to any server, through which the mold data set and casting parameter set provided by the casting operator are obtained, and the vacuum casting process is simulated according to the mold data set and the casting parameter set to obtain the simulation results, and on this basis, the simulation results are screened according to the mold data set to determine the key impact data set of the seal that will have a direct impact on the mold seal in the vacuum casting process in the simulation results, and the potential risks of the seal in the vacuum casting process are analyzed in combination with the seal parameter set, and the potential risk information of the seal is obtained, and based on the potential risk information of the seal, a risk report and suggestion information are generated and output, so that the casting operator can intuitively understand the state of the seal and the direction of reducing the potential risk of the seal, and realize the scientific analysis of the potential risk of the mold seal in the vacuum casting process, so that the potential risk of the seal can be discovered and reduced in time, thereby improving the quality and qualified rate of the final casting. The specific implementation method can refer to the following embodiments.

[0070] Figure 2 This is a flowchart of a casting quality control method based on Magmasoft provided in one 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:

[0071] S201, obtaining a mold data set and a casting parameter set, simulating a vacuum casting process according to the mold data set and the casting parameter set, and determining a simulation result.

[0072] The mold data set may be a data set containing various parameters related to the vacuum casting mold, such as parameters such as the mold set shape and material properties, and the mold data set may be provided by a casting operator.

[0073] The casting parameter set may be a data set including various required parameters of the vacuum casting process, such as pressure, speed and other process parameters in the vacuum casting process. The casting parameter set may be provided by a casting operator.

[0074] The simulation result may be a data set including the changes of various parameters during the vacuum casting simulation process, such as the temperature field, pressure field, flow field and other data during the vacuum casting process.

[0075] Specifically, vacuum casting is an efficient casting process. The vacuum environment helps the metal liquid to fill the mold better, can effectively reduce the gas content in the casting, ensure the density and strength of the casting, improve the mechanical properties and toughness of the casting, and the vacuum casting operation process is relatively fast, which can achieve high-efficiency production and is suitable for mass production. Magmasoft can be used to simulate the vacuum casting process in a way that fits the actual casting process, so as to improve the current vacuum casting process according to the simulation results before formal production, thereby improving the qualified rate of castings in the actual casting process. However, since the mold needs to be kept in a vacuum state during the vacuum casting process, seals need to be set at key parts of the mold to prevent external air from leaking into the mold. In the vacuum casting simulation process, the prior art can perform a relatively mature and comprehensive simulation of the state changes of the molten metal inside the mold, but it is difficult to accurately analyze the state changes of the seals under continuous influence during the vacuum casting process, resulting in a split between the simulation results and the actual casting results, that is, when the simulation results point to a high qualified rate, the qualified rate of the castings corresponding to the actual casting results does not meet the standard. Therefore, the Magmasoft simulation results cannot be used alone as the basis for seal status assessment. Instead, Magmasoft should be used to obtain simulation results including various changing parameters in the vacuum casting process based on the mold data set and casting parameter set provided by the casting operator. This can be used as the data basis for seal status assessment and provide a scientific data framework for the subsequent proprietary analysis process of potential risks of seals.

[0076] S202, analyzing the mold data set, screening the simulation results, and determining the key influencing data set of the seal.

[0077] The seal key impact data set may be a data set that directly affects the seals in the mold during vacuum casting.

[0078] Specifically, since the simulation results are obtained by Magmasoft to simulate the entire vacuum casting process, the simulation results contain all the data that can reflect the impact of the molten metal on each part of the mold during the vacuum casting process. However, only the data corresponding to some mold areas in the simulation results can directly affect the state of the seals during the vacuum casting process. In order to avoid data redundancy and to improve the pertinence and accuracy of the subsequent potential risk analysis process of seals, the massive data in the simulation results are screened according to the areas where the seals are located reflected in the mold data set, and some data that can affect the state of the seals in the corresponding areas of the seals are determined. Based on these data, a key impact data set of seals is constructed to provide data guarantee for the high pertinence of the subsequent potential risk analysis process of seals.

[0079] S203: Obtain a seal parameter set, analyze a seal key impact data set based on the seal parameter set, and determine potential risk information of the seal.

[0080] The seal parameter set may be a set of parameters that can reflect the characteristics of the seal itself, such as material characteristics, etc. The seal parameter set may be provided by a casting operator.

[0081] The potential risk information of the seal may be information that can reflect the potential risks of the seal in the vacuum casting process.

[0082] Specifically, there are objective differences in the impacts on seals with different characteristics under the same vacuum casting process. In the process of analyzing the state of seals in the vacuum casting process, it is necessary to introduce a seal parameter set representing the characteristics of the seals to further improve the targeted analysis of the potential risks of the seals. On the basis of the seal parameter set, mathematical analysis methods are used to describe the impact of the seal key influence data on the seals pointed to by the seal parameter set during the vacuum casting process according to the seal key influence data set, and then the interaction relationship between the seal key influence data set, the seal parameter set and the potential risks of the seal is quantified to obtain the potential risk information of the seal that can reflect the state of the seal.

[0083] S204. Determine and output risk report and suggestion information based on the potential risk information of the seal.

[0084] The risk report may be formal seal risk report information generated based on seal potential risk information.

[0085] The suggestion information may be suggestion information obtained based on the potential risk information of the seal and used for reference by the casting operator to reduce the potential risk of the seal.

[0086] Specifically, after obtaining the potential risk information of the seal, a risk report is generated through data visualization technology to enable the casting operator to intuitively understand the status of the seal. When the potential risk of the seal will directly affect the quality of the casting during the vacuum casting process, the direction of reducing the potential risk of the seal is determined according to the potential risk information of the seal, such as improving the seal material or fine-tuning the casting process, and the corresponding suggestion information in this direction is simultaneously provided to the casting operator to reduce the potential risk of the seal and improve the quality of the casting.

[0087] Through this scheme, the vacuum casting process is simulated according to the mold data set and the casting parameter set to obtain the simulation results, and on this basis, the simulation results are screened according to the mold data set to determine the key influencing data set of seals that will have a direct impact on the mold seals in the vacuum casting process in the simulation results, and based on this, combined with the seal parameter set, the potential risks of seals in the vacuum casting process are analyzed to obtain the potential risk information of seals, and based on the potential risk information of seals, risk reports and recommendation information are generated and output for casting operators to intuitively understand the status of seals and the direction of reducing potential risks of seals, thereby realizing a scientific analysis of the potential risks of mold seals in the vacuum casting process, so that the potential risks of seals can be discovered and reduced in time, thereby improving the quality and pass rate of the final castings.

[0088] In some embodiments, a mold data set is imported into Magmasoft, a mold three-dimensional model is determined, and mold material data corresponding to the mold three-dimensional model is defined according to a casting parameter set; vacuum system parameters, casting conditions and casting materials are defined according to the casting parameter set; a flow rate simulation data set, a temperature simulation data set, a pressure simulation data set and a stress simulation data set simulated by Magmasoft based on the mold three-dimensional model and the mold material data, according to the vacuum system parameters, casting conditions and casting materials are received; and the flow rate simulation data set, the temperature simulation data set, the pressure simulation data set and the stress simulation data set are used as simulation results.

[0089] The mold three-dimensional model may be a three-dimensional collective model corresponding to the mold in the vacuum casting process, and is used to simulate the mold used in the actual casting process.

[0090] The mold material data may be a series of data that can reflect the physical properties of the current mold material.

[0091] The vacuum system parameters may be parameters required to achieve a vacuum environment corresponding to the vacuum casting process, such as vacuum degree, exhaust rate, etc.

[0092] The casting conditions may be a series of condition variables that need to be controlled when casting a target product using a vacuum casting process, such as temperature, pressure, etc.

[0093] The casting material may be data corresponding to the material required to cast the target product.

[0094] The flow velocity simulation data set may be a data set of flow velocity distribution and variation of the molten metal fluid in the vacuum casting process obtained by simulation;

[0095] The temperature simulation data set may be a data set of temperature distribution and variation inside the mold and casting body obtained by simulation during vacuum casting;

[0096] The pressure simulation data set may be a data set of pressure distribution and changes inside the mold and the casting body obtained by simulation during the vacuum casting process;

[0097] The stress simulation data set may be a data set of stress distribution and changes inside the mold and the casting obtained by simulation during the vacuum casting process.

[0098] Specifically, in the simulation of vacuum casting, the mold data set is imported into Magmasoft, and based on the corresponding three-dimensional mold model of Magmasoft and the casting parameter set, the mold material data corresponding to the three-dimensional mold model is annotated using the built-in material database of Magmasof. At the same time, according to the casting parameter set, the vacuum system parameters required for the current vacuum casting process are defined through the built-in vacuum environment setting function of Magmasoft, and the casting conditions and casting materials are defined using the built-in parameter setting module and casting material library of Magmasoft. Based on the mold three-dimensional model and mold material data, according to the vacuum system parameters, casting conditions and casting materials, the casting simulation module of Magmasoft is used to simulate the entire vacuum casting process, thereby obtaining the flow velocity simulation data set, temperature simulation data set, pressure simulation data set and stress simulation data set corresponding to the vacuum casting process, and these data sets are used as simulation results.

[0099] Through this solution, Magmasoft is used to create, define and set the mold 3D model, mold material data, vacuum system parameters, casting conditions and casting materials required for the vacuum casting simulation process according to the mold data set and casting parameter set. On this basis, the vacuum casting process is simulated to obtain the flow rate simulation data set, temperature simulation data set, pressure simulation data set and stress simulation data set. The above series of data sets are used as simulation results to provide scientific data basis for the subsequent potential risk analysis process of seals.

[0100] In some embodiments, based on the mold data set, the seal contact surface in the mold is extracted; according to a preset division rule, a number of analysis points are set in the mold model geometry corresponding to the mold data set, and the relative distance between each analysis point and the seal contact surface is extracted; based on the number of analysis points, the simulation results are analyzed, and the fluid flow rate value, temperature value, pressure value and stress value corresponding to each analysis point are extracted; based on the mold material data, the flow rate influence lower limit, pressure influence lower limit, temperature influence lower limit and stress influence lower limit are determined; based on the seal contact surface, the mold model and the relative distance, according to the flow rate influence lower limit, pressure influence lower limit, temperature influence lower limit and stress influence lower limit, the fluid flow rate value, temperature value, pressure value and stress value corresponding to each analysis point are analyzed to determine a set of key analysis points; based on the simulation data corresponding to the key analysis point set in the simulation results, the seal key influence data set is determined.

[0101] The seal contact surface may be the surface of the mold geometry that is in direct contact with the seal surface.

[0102] The preset division rule may be a preset rule for dividing the analysis points in the mold geometry. The preset division rule may include a provision for the number of analysis points per unit area of ​​the mold geometry. The preset division rule may be set according to the complexity of the mold.

[0103] The analysis point can be a coordinate point within the mold geometry that is the object of simulation data analysis.

[0104] The flow velocity influence lower limit may be a lower limit value of the molten metal fluid flow velocity that can affect the adjacent sealing member within a fixed range.

[0105] The pressure influence lower limit may be a lower limit value of the influence that the internal pressure of the mold can have on the adjacent sealing member within a fixed range.

[0106] The temperature influence lower limit may be a lower limit value of the influence that the internal temperature of the mold can have on the adjacent sealing member within a fixed range.

[0107] The lower limit of stress influence can be the lower limit value of the influence that the internal stress of the mold can have on the adjacent seal within a fixed range.

[0108] Specifically, in the process of screening the simulation results, the closer the position of the mold assembly structure corresponding to the data in the simulation results is to the contact surface between the mold and the seal, the more significant the impact of the data on the seal. Therefore, based on the mold data set, the seal contact surface in the mold is determined and extracted. Considering that the seal contact surface and other mold assembly structures are composed of countless points, it is impossible to analyze the simulation data corresponding to each point one by one. In order to improve data analysis efficiency, a number of analysis points are divided in the mold model geometry structure according to preset division rules. Since the relative distance between the analysis point and the seal contact surface directly affects the degree of influence of various types of simulation data corresponding to the analysis point on the seal, the vertical distance between each analysis point and the seal contact surface is calculated through the coordinate point distance formula. , using this as a relative distance to provide a basis for screening simulation results. At the same time, since the influence of flow velocity, pressure, temperature and stress at different analysis points on the seal is limited to a certain distance, and the lower limit of the influence of different types of simulation data within a certain distance is directly constrained by the mold material, by conducting simulation experiments on different mold materials and collecting experimental data, it is possible to analyze the lower limit of flow velocity influence, pressure influence, temperature influence and stress influence of the current mold material within a certain relative distance around the seal. In this way, the fluid flow velocity value, temperature value, pressure value and stress value corresponding to each analysis point are analyzed. When the corresponding data value exceeds the corresponding lower limit of influence, it will be regarded as an effective influence, further realizing the refinement and screening of simulation results, reducing data redundancy and improving analysis results.

[0109] Through this solution, based on the mold data set, the seal contact surface that is in direct contact between the mold and the seal is extracted. Based on this, the relative distances between the different analysis points obtained and the seal contact surface are extracted. At the same time, based on the mold material data, the flow velocity influence lower limit, pressure influence lower limit, temperature influence lower limit and stress influence lower limit corresponding to each type of data in the simulation results are determined. Based on this, the fluid flow velocity value, temperature value, pressure value and stress value corresponding to each analysis point are analyzed to obtain a set of key analysis points, and the seal key influence data set is constructed based on this, which effectively focuses the analysis on the key area around the seal, while reducing the interference of irrelevant data, enhancing the pertinence and efficiency of subsequent potential risk analysis of the seal, and significantly reducing the calculation complexity while ensuring data accuracy.

[0110] In some embodiments, based on the seal contact surface, the mold model and the relative distance, according to the flow rate influence lower limit, the pressure influence lower limit, the temperature influence lower limit and the stress influence lower limit, the fluid flow rate value, temperature value, pressure value and stress value corresponding to each analysis point are analyzed to determine the key analysis point set, which is specifically the following formula (1):

[0111] R ={ I ∈ M}∨{ I ∈ Oh ∧ d I < D | V I ≥ V n ∨ P I ≥ P n ∨ T I ≥ T n ∨ s I ≥ s n};

[0112] in, R is the key analysis point set, I is the current analysis point, M is the seal contact surface, Oh is the mold model geometry, d I is the relative distance between the current analysis point and the contact surface of the seal, D is the preset distance threshold, V I is the fluid velocity value corresponding to the current analysis point, V n is the lower limit of the flow velocity, P I is the pressure value corresponding to the current analysis point, P n is the lower limit of the pressure influence, T I is the temperature value corresponding to the current analysis point, T n is the lower limit of the temperature influence, s I is the stress value corresponding to the current analysis point, s n is the lower limit of the stress influence.

[0113] The preset distance threshold may be a maximum effective influence distance between a preset analysis point and the contact surface of the seal, and the preset distance threshold may be obtained by analyzing experimental data of different mold materials.

[0114] Specifically, since all analysis points on the seal contact surface are in direct contact with the seal, the formula (1) is I∈ M All the analysis points belonging to the seal contact surface are included in the key analysis point set, and at the same time I ∈ Oh ∧ d I < D The remaining key analysis points must be within the mold model geometry and the relative distance between them and the seal contact surface must be less than the preset distance threshold to eliminate irrelevant data and then use V I ≥ V n ∨ P I ≥ P n ∨ T I ≥ T n ∨ s I ≥ s n , the remaining key analysis points must satisfy the requirement that at least one data value exceeds the corresponding lower limit of influence, so as to further refine the valid data in the simulation results. Through the coordination of the above conditions, the automatic batch screening of the simulation results can be realized.

[0115] Through this solution, mathematical analysis methods are used, based on the seal contact surface, mold model and relative distance, according to the lower limits of flow rate influence, pressure influence, temperature influence and stress influence, and scientific restrictions are placed on the requirements of the key analysis points in the key analysis point set through clear mathematical language. Combined with the fluid flow rate value, temperature value, pressure value and stress value corresponding to each analysis point, automatic batch screening of simulation results is achieved, and a highly refined set of key analysis points required for the subsequent potential analysis process of the seal is obtained. Data redundancy is significantly reduced by removing irrelevant data and refining valid data.

[0116] In some embodiments, material characteristic factors are determined based on the tensile strength and thermal expansion coefficient of the material; based on the seal key influence data set, the fluid flow rate values, temperature values, pressure values ​​and stress values ​​corresponding to all key analysis points are sorted in ascending order, and based on the sorting results, the high quantile flow rate value, high quantile temperature value, high quantile pressure value and high quantile stress value are determined; based on the high quantile flow rate value, high quantile temperature value, high quantile pressure value and high quantile stress value, the external comprehensive influencing factor is determined; the material characteristic factors and the external comprehensive influencing factors are analyzed to determine the comprehensive potential risk value, and the comprehensive potential risk value, the material characteristic factors and the external comprehensive influencing factors are determined as the potential risk information of the seal.

[0117] The seal parameter set includes material tensile strength and coefficient of thermal expansion.

[0118] The tensile strength of a material can be a quantitative value used to characterize the ability of a seal to resist deformation.

[0119] The coefficient of thermal expansion can be a quantitative value used to characterize the degree to which a seal deforms under the influence of temperature changes.

[0120] The material characteristic factor can be a mathematical quantitative factor used to characterize the impact of the material properties of the seal itself on its potential risk.

[0121] The high percentile flow rate value may be a flow rate value at a specified high percentile in the ascending fluid flow rate value set, and the specified high percentile may be a 95% percentile.

[0122] The high quantile temperature value may be a temperature value at a specified high quantile in the ascending temperature value set.

[0123] The high percentile pressure value may be a pressure value at a specified high percentile in the ascending pressure value set.

[0124] The high quantile stress value may be a stress value at a specified high quantile within a set of ascending stress values.

[0125] The external comprehensive influencing factor can be a mathematical quantitative factor used to characterize the impact of various external factors on the potential risk of seals.

[0126] The comprehensive potential risk value can be a quantitative value that reflects the potential risks of the seal under both its own and external influences.

[0127] Specifically, during the vacuum casting process, the potential risks of the seals in the mold are mainly affected by their own material properties and external factors. Among them, the material properties themselves are mainly reflected by the tensile strength and thermal expansion coefficient. The tensile strength of the seal determines whether it can maintain effective sealing when subjected to mechanical stress. If the tensile strength is insufficient, the seal may fail in a vacuum environment, resulting in gas leakage; under high temperature conditions, especially during the casting process, the thermal expansion of the material may cause poor contact between the seal and the mold, increasing the risk of leakage. Materials with too high a thermal expansion coefficient will expand too much when heated, which may cause the seal to deform or even damage the mold. Through mathematical analysis, the tensile strength and thermal expansion coefficient of the material are analyzed, and the material characteristic factors that can reflect the impact of the seal material properties on potential risks are quantified.

[0128] External factors mainly include fluid flow rate, temperature, pressure and stress. The fluid flow rate affects the temperature and cooling effect of the mold and its surrounding materials. Local overheating or overcooling will cause stress to the seal and increase the risk of gas damage. Uneven temperature distribution will lead to temperature differences between adjacent areas of the seal, thereby generating thermal stress, which may cause fatigue damage or deformation of the seal material. At the same time, different seals have different thermal expansion coefficients. Uneven temperature will cause inconsistent dimensional changes of the seal, affecting the sealing performance. Non-uniform distribution of pressure may cause stress concentration around the seal, causing certain areas to bear excessive local pressure, increasing the risk of cracks or tears. Under higher pressure environments, the failure mode of the seal may change, such as from material rupture to shape deformation, thereby affecting the molding quality of the casting. During the casting process, over time, the seal may undergo permanent deformation due to continuous stress, resulting in a decrease in the sealing effect. In view of the above-mentioned influences, it is necessary to conduct a comprehensive analysis and assessment of the seal material properties and external influencing factors during the potential risk analysis of the seals. However, due to the existence of many key analysis points, it is necessary to further select representative data therefrom in order to quickly determine the potential risks of the seals. Through a quick sorting algorithm, the fluid flow rate values, the temperature values, the pressure values, and the stress values ​​corresponding to all key analysis points are sorted in ascending order, and the corresponding high quantile flow rate values, high quantile temperature values, high quantile pressure values, and high quantile stress values ​​are selected therefrom. By selecting high quantile values, representative data is selected while avoiding the influence of extreme values. The above-mentioned high quantile values ​​can be selected in multiple high quantiles. The method is to select high percentile values ​​for multiple times in a high percentile interval, such as 80% to 95%, and use the high percentile values ​​selected each time as the parameter basis for determining the external comprehensive influencing factors. The corresponding external comprehensive influencing factors are quantified by mathematical analysis, and the average value of several external comprehensive influencing factors is taken as the final representative external comprehensive influencing factors to further improve the accuracy of the external comprehensive influencing factors. After obtaining the material characteristic factors and the external comprehensive influencing factors, the comprehensive potential risk value of the seal under the above-mentioned dual influences is obtained by mathematical analysis, and the comprehensive potential risk value, material characteristic factors and external comprehensive influencing factors are determined as the potential risk information of the seal.

[0129] Through this scheme, according to the tensile strength and thermal expansion coefficient of the material, the material characteristic factors that can reflect the impact of the material characteristics of the seal on the potential risks are analyzed and determined. At the same time, the high percentile flow rate value, high percentile temperature value, high percentile pressure value and high percentile stress value are determined by selecting high percentile values ​​to ensure the representativeness of the data. On this basis, the external comprehensive influencing factors that can reflect the comprehensive impact of external influencing factors on the potential risks of the seal are analyzed and obtained. Through the combined analysis of the material characteristic factors and the external comprehensive influencing factors, the comprehensive potential risk value of the seal under the above-mentioned dual influences is obtained, and the comprehensive potential risk value, material characteristic factors and external comprehensive influencing factors are determined as the potential risk information of the seal, thereby improving the accuracy and comprehensiveness of the potential risks of the seal.

[0130] In some embodiments, the material characteristic factors and the external comprehensive influencing factors are analyzed to determine the comprehensive potential risk value, which is specifically the following formula (2):

[0131] (2)

[0132] in, G is the comprehensive potential risk value, A is the preset strength relationship coefficient, B To preset the intensity influence adjustment index, S is the tensile strength of the material, f is the preset temperature response index, L is the preset temperature influence coefficient, E is the thermal expansion coefficient, is the material characteristic factor, H is the external comprehensive influencing factor.

[0133] The preset strength relationship coefficient may be a quantitative value reflecting the linear effect of the tensile strength of the seal on the potential risk of the seal, and the preset strength relationship coefficient may be obtained by fitting the experimental data of the seal.

[0134] The preset strength influence adjustment index may be a value used to adjust the influence of the tensile strength of the seal on the potential risk of the seal. The preset strength influence adjustment index may be obtained by fitting the experimental data of the seal.

[0135] The preset temperature response index may be a quantitative value reflecting the direct impact of temperature-induced thermal expansion of the seal on the potential risk of the seal. The preset temperature response index may be obtained by fitting the seal experimental data.

[0136] The preset temperature influence coefficient may be a quantitative value used to adjust the nonlinear effect of temperature-induced thermal expansion of the seal on the potential risk of the seal. The preset temperature influence coefficient may be obtained by fitting the seal experimental data.

[0137] Specifically, through formula (2) Describe the effect of material tensile strength on the potential risk of seals. The exponential function can reflect the nonlinear effect of the potential risk under the ultimate strength. As the tensile strength increases, the potential risk decreases. When the tensile strength approaches the limit, the potential risk decreases rapidly. Describes the effect of thermal expansion under the influence of temperature on potential risks. When the thermal expansion coefficient is too high, the potential risk increases rapidly. The material characteristic factors are comprehensively quantified to reflect the potential risk performance of seals under the influence of material properties. Combined with external comprehensive influencing factors, the scientific quantification of the comprehensive potential risk value is achieved.

[0138] Through this scheme, mathematical analysis is used to describe the nonlinear effects of material tensile strength and thermal expansion coefficient on the potential risks of seals, so as to quantify material characteristic factors. Combined with external comprehensive influencing factors, scientific quantification of the comprehensive potential risk value is achieved, thereby improving the accuracy and comprehensiveness of the comprehensive potential risk value analysis process.

[0139] In some embodiments, the external comprehensive influencing factor is determined according to the high quantile flow rate value, the high quantile temperature value, the high quantile pressure value and the high quantile stress value, which is specifically the following formula (3):

[0140] (3)

[0141] in, V is the high percentile flow rate value, α is the preset velocity influence condition coefficient, β The preset temperature affects the adjustment index. T is the high quantile temperature value, T 0 is the preset reference temperature value, P is the high percentile pressure value, C is the preset pressure threshold, s is the high quantile stress value, s 0 is the default stress reference.

[0142] The preset flow velocity influencing condition coefficient may be a coefficient used to adjust the strength of the interaction relationship between the flow velocity and the external comprehensive influencing factors. The preset flow velocity influencing condition coefficient may be obtained by fitting the sealing component experimental data.

[0143] The preset temperature influence adjustment index may be a coefficient used to adjust the strength of the interaction relationship between temperature and external comprehensive influencing factors. The preset temperature influence adjustment index may be obtained by fitting the experimental data of the sealing component.

[0144] The preset reference temperature value may be a temperature reference value used to measure the degree of deviation of the current temperature value, and the preset reference temperature value may be set according to actual needs.

[0145] The preset stress reference may be a stress reference value used to measure the degree of deviation of the current stress value, and the preset stress reference may be set according to actual needs.

[0146] Specifically, through formula (3) Describes the effect of flow rate on the external comprehensive influencing factor, the denominator is 1+ αV 2 It means that the influence of flow velocity has nonlinear regulation. When the flow velocity is large enough, the external comprehensive influence factor will tend to , reflecting that the influence of flow velocity tends to be saturated when it reaches a certain level, which is consistent with the flow velocity characteristics of the molten metal fluid in the casting process. Reflects the effect of temperature on the external comprehensive influencing factors. When the temperature increases significantly, the corresponding external comprehensive influencing factors will also increase significantly, which is consistent with the effect of increased temperature on the stability of the seal. Reflects the impact of pressure on external comprehensive influencing factors, and at the same time Describes the influence of stress on external comprehensive influencing factors. When the stress is smaller than the stress reference, the influence of stress on the external comprehensive influencing factors is smaller. As the stress increases, the influence of stress on the external comprehensive influencing factors gradually becomes apparent.

[0147] Through this scheme, mathematical analysis is used to describe the nonlinear effects of flow, temperature, pressure and stress on the potential risks of seals based on high quantile flow velocity values, high quantile temperature values, high quantile pressure values ​​and high quantile stress values ​​through clear mathematical relationships, so as to quantify the external comprehensive influencing factors, thereby ensuring the scientificity and comprehensiveness of the external comprehensive influencing factors.

[0148] In some embodiments, the comprehensive potential risk value in the potential risk information is compared with a preset risk threshold to determine whether the comprehensive potential risk value exceeds the preset risk threshold; if the comprehensive potential risk value exceeds the preset risk threshold, the influence ratio of material characteristic factors and external comprehensive influencing factors on the comprehensive potential risk value is analyzed and determined; if the influence ratio of material characteristic factors is greater than the influence ratio of external comprehensive influencing factors, the sealing material re-evaluation requirement is output as suggestion information; if the influence ratio of external comprehensive influencing factors is greater than the influence ratio of material characteristic factors, the casting process re-evaluation requirement is output as suggestion information; based on the potential risk information, the influence ratio of material characteristic factors and the influence ratio of external comprehensive influencing factors, a risk report is constructed and output.

[0149] The preset risk threshold may be a potential risk value of the seal corresponding to the negative impact on the seal quality, and the preset risk threshold may be obtained by fitting based on the experimental data of the seal.

[0150] The seal material re-evaluation requirement may be a requirement to re-evaluate the material properties of the seal.

[0151] The casting process re-evaluation requirement may be a requirement for re-evaluating the casting process.

[0152] Specifically, after determining the potential risk information of the seal, the comprehensive potential risk value is compared with the preset risk threshold to determine whether the current potential risk of the seal will cause the quality of the casting to deteriorate. If the comprehensive potential risk value exceeds the preset risk threshold, it means that the potential risk corresponding to the seal will lead to a gradual quality degradation. At this time, it is necessary to locate the decisive factors affecting the potential risk of the seal. By comparing the influence ratio of material characteristic factors and external comprehensive influencing factors, the above-mentioned decisive factors are located, and the corresponding recommended information is determined based on the decisive factors.

[0153] Through this solution, at the stage of outputting risk reports and recommendation information, by comparing the influence ratios of material characteristic factors and external comprehensive influencing factors, the decisive factors affecting the potential risks of seals are further located, so as to determine the corresponding recommendation information, so that the casting operators who receive the recommendation information can clarify the subsequent improvement direction, so as to indirectly improve the quality of castings.

[0154] In some embodiments, based on the mold data set, the mold flying material risk and the corresponding high-risk flying material areas in the demolding stage are evaluated according to the vacuum system parameters, casting conditions and casting materials; the mold flying material risk is compared with the preset flying material risk threshold. If the mold flying material risk exceeds the preset flying material risk threshold, the mold flying material risk is included in the risk report, and the high-risk flying material areas are included in the recommendation information.

[0155] The risk of mold flying material may be the risk of flying material caused during the mold separation process in the demoulding stage.

[0156] The high-risk area for flying materials may be the main distribution area of ​​flying materials on the casting and the mold.

[0157] The preset flying material risk threshold may be a risk threshold corresponding to the negative impact that the flying material phenomenon may have on the quality of the current casting or the quality of subsequent castings.

[0158] Specifically, the flying material phenomenon in the vacuum casting process may occur in the demolding stage. The vacuum state inside the mold is broken in this stage, and flying material may be caused during the state switching process. The flying material phenomenon will cause traces of molten metal splashing on the surface of the casting, forming burrs, pores or other surface defects. At the same time, the flying material phenomenon may also cause metal flying materials to adhere to the inside of the mold, thereby causing the subsequent casting quality to fail to meet the standards. Therefore, after completing the simulation of the casting process, it is necessary to further simulate the metal flying material situation in the demolding stage based on Magmasoft to obtain the mold flying material risk and the corresponding high-risk flying material area. The mold flying material wind can be used to determine whether the current mold flying material risk will affect the casting quality, and the high-risk flying material area can further clarify the differentiated impact of flying material on castings and molds. This can be used as recommended information to enable the corresponding personnel to further optimize the vacuum casting process according to the mold flying material situation, thereby further improving the casting quality.

[0159] Through this plan, the mold flying material risk and the corresponding high-risk areas of flying material during the demolding stage of the vacuum casting process are analyzed and determined to clarify whether the current mold flying material risk will affect the quality of the casting. At the same time, the differentiated impact of flying material on castings and molds is clarified, so that the corresponding personnel can further optimize the vacuum casting process according to the mold flying material situation, thereby further improving the quality of castings.

[0160] Figure 3 A structural diagram of a casting quality control system based on Magmasoft provided in one embodiment of the present application, such as Figure 3 As shown, a casting quality control system 300 based on Magmasoft in this embodiment includes: a casting simulation module 301 , a data screening module 302 , a risk analysis module 303 , and an output module 304 .

[0161] A casting simulation module 301 is used to obtain a mold data set and a casting parameter set, simulate a vacuum casting process according to the mold data set and the casting parameter set, and determine a simulation result;

[0162] A data screening module 302 is used to analyze the mold data set, screen the simulation results, and determine a seal key impact data set;

[0163] The risk analysis module 303 is used to obtain a seal parameter set, analyze the seal key impact data set based on the seal parameter set, and determine the potential risk information of the seal;

[0164] The output module 304 is used to determine and output risk reports and suggestion information based on the potential risk information of the seal.

[0165] Optionally, the casting simulation module 301 is specifically used for:

[0166] Importing the mold data set into Magmasoft, determining the mold three-dimensional model, and defining the mold material data corresponding to the mold three-dimensional model according to the casting parameter set;

[0167] According to the casting parameter set, vacuum system parameters, casting conditions and casting materials are defined;

[0168] Receiving a flow rate simulation data set, a temperature simulation data set, a pressure simulation data set and a stress simulation data set simulated by Magmasoft based on the mold three-dimensional model and the mold material data, according to the vacuum system parameters, the casting conditions and the casting material;

[0169] The flow velocity simulation data set, the temperature simulation data set, the pressure simulation data set and the stress simulation data set are taken as the simulation results.

[0170] Optionally, the data screening module 302 is specifically used for:

[0171] Extracting a seal contact surface in the mold according to the mold data set;

[0172] According to a preset division rule, a plurality of analysis points are set in the mold model geometry structure corresponding to the mold data set, and a relative distance between each of the analysis points and the seal contact surface is extracted;

[0173] Analyze the simulation results according to the plurality of analysis points, and extract the fluid velocity value, temperature value, pressure value and stress value corresponding to each analysis point;

[0174] According to the mold material data, determining the lower limit of flow velocity influence, the lower limit of pressure influence, the lower limit of temperature influence and the lower limit of stress influence;

[0175] Based on the seal contact surface, the mold model and the relative distance, and according to the flow velocity influence lower limit, the pressure influence lower limit, the temperature influence lower limit and the stress influence lower limit, the fluid flow velocity value, the temperature value, the pressure value and the stress value corresponding to each analysis point are analyzed to determine a set of key analysis points;

[0176] A seal key influencing data set is determined according to simulation data corresponding to the key analysis point set in the simulation result.

[0177] Optionally, the data screening module 302 analyzes the fluid flow rate value, the temperature value, the pressure value and the stress value corresponding to each analysis point based on the seal contact surface, the mold model and the relative distance, according to the flow rate influence lower limit, the pressure influence lower limit, the temperature influence lower limit and the stress influence lower limit, and determines the key analysis point set by the following formula:

[0178] R ={ I ∈ M}∨{ I ∈ Oh ∧ d I < D | V I ≥ V n ∨ P I ≥ P n ∨ T I ≥ T n ∨ s I ≥ s n}

[0179] in, R is the set of key analysis points, I is the current analysis point, M is the seal contact surface, Oh is the mold model geometry, d I is the relative distance between the current analysis point and the contact surface of the seal, D is the preset distance threshold, V I is the fluid velocity value corresponding to the current analysis point, V n is the lower limit of the flow velocity, P I is the pressure value corresponding to the current analysis point, P n is the lower limit of the pressure influence, T I is the temperature value corresponding to the current analysis point, T n is the lower limit of the temperature influence, s I is the stress value corresponding to the current analysis point, s n is the lower limit of the stress influence.

[0180] Optionally, the risk analysis module 303 is specifically used to:

[0181] Determining a material characteristic factor according to the material tensile strength and the thermal expansion coefficient;

[0182] According to the seal key impact data set, the fluid flow rate values, the temperature values, the pressure values ​​and the stress values ​​corresponding to all key analysis points are sorted in ascending order, and according to the sorting results, a high quantile flow rate value, a high quantile temperature value, a high quantile pressure value and a high quantile stress value are determined;

[0183] Determining an external comprehensive influencing factor according to the high quantile flow velocity value, the high quantile temperature value, the high quantile pressure value and the high quantile stress value;

[0184] The material characteristic factors and the external comprehensive influencing factors are analyzed to determine a comprehensive potential risk value, and the comprehensive potential risk value, the material characteristic factors and the external comprehensive influencing factors are determined as the potential risk information of the seal.

[0185] Optionally, when the risk analysis module 303 analyzes the material characteristic factor and the external comprehensive influencing factor to determine the comprehensive potential risk value, it is specifically the following formula:

[0186] ;

[0187] in, G is the comprehensive potential risk value, A is the preset strength relationship coefficient, B To preset the intensity influence adjustment index, S is the tensile strength of the material, f is the preset temperature response index, L is the preset temperature influence coefficient, E is the thermal expansion coefficient, is the material characteristic factor, H is the external comprehensive influencing factor.

[0188] Optionally, when the risk analysis module 303 determines the external comprehensive influencing factor according to the high quantile flow rate value, the high quantile temperature value, the high quantile pressure value and the high quantile stress value, it is specifically the following formula:

[0189] ;

[0190] in, V is the high percentile flow rate value, α is the preset velocity influence condition coefficient, βThe preset temperature affects the adjustment index. T is the high percentile temperature value, T 0 is the preset reference temperature value, P is the high percentile pressure value, C is the preset pressure threshold, s is the high quantile stress value, s 0 is the default stress reference.

[0191] Optionally, the output module 304 is specifically used to:

[0192] Comparing the comprehensive potential risk value in the potential risk information with a preset risk threshold to determine whether the comprehensive potential risk value exceeds the preset risk threshold;

[0193] If the comprehensive potential risk value exceeds the preset risk threshold, analyzing and determining the influence ratio of the material characteristic factor and the external comprehensive influencing factor on the comprehensive potential risk value;

[0194] If the influence ratio of the material characteristic factor is greater than the influence ratio of the external comprehensive influencing factor, the seal material re-evaluation requirement is output as the recommendation information;

[0195] If the influence ratio of the external comprehensive influencing factors is greater than the influence ratio of the material characteristic factors, the casting process re-evaluation requirement is output as the suggestion information;

[0196] The risk report is constructed and output based on the potential risk information, the impact ratio of the material characteristic factors and the impact ratio of the external comprehensive influencing factors.

[0197] Optionally, the system 300 further includes a flying material analysis module 305, which is used to:

[0198] Based on the mold data set, according to the vacuum system parameters, the casting conditions and the casting materials, evaluating the mold flying risk and the corresponding flying high-risk area in the demolding stage;

[0199] The mold flying material risk is compared with a preset flying material risk threshold. If the mold flying material risk exceeds the preset flying material risk threshold, the mold flying material risk is included in the risk report, and the flying material high-risk area is focused on and included in the recommendation information.

[0200] 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 quality control method based on Magmasoft, characterized in that: include: S1. Obtain a mold data set and a casting parameter set, import the mold data set into Magmasoft, determine a mold three-dimensional model, and define mold material data, vacuum system parameters, casting conditions and casting materials corresponding to the mold three-dimensional model according to the casting parameter set; Based on the mold three-dimensional model and the mold material data, according to the vacuum system parameters, casting conditions and casting materials, simulate a flow rate simulation data set, a temperature simulation data set, a pressure simulation data set and a stress simulation data set; the flow rate simulation data set, the temperature simulation data set, the pressure simulation data set and the stress simulation data set are used as the simulation results; S2, analyzing the mold data set, screening the simulation results, and determining a key impact data set of the seal; S3, obtaining a seal parameter set, and based on the seal parameter set, analyzing the seal key impact data set to determine the seal potential risk information; S4. Determine and output risk report and suggestion information based on potential risk information of seals; The S2 comprises: Extracting a seal contact surface in the mold according to the mold data set; According to a preset division rule, a plurality of analysis points are set in the mold model geometry structure corresponding to the mold data set, and a relative distance between each analysis point and the contact surface of the seal is extracted; Analyze the simulation results according to the plurality of analysis points, and extract the fluid velocity value, temperature value, pressure value and stress value corresponding to each analysis point; According to the mold material data, determining the lower limit of flow velocity influence, the lower limit of pressure influence, the lower limit of temperature influence and the lower limit of stress influence; Based on the seal contact surface, the mold model and the relative distance, and according to the flow velocity influence lower limit, the pressure influence lower limit, the temperature influence lower limit and the stress influence lower limit, the fluid flow velocity value, the temperature value, the pressure value and the stress value corresponding to each analysis point are analyzed to determine a set of key analysis points; Determine a seal key impact data set according to simulation data corresponding to the key analysis point set in the simulation result; The seal parameter set includes material tensile strength and thermal expansion coefficient, and S3 includes: Determining a material characteristic factor according to the material tensile strength and the thermal expansion coefficient; According to the seal key impact data set, the fluid flow rate values, the temperature values, the pressure values ​​and the stress values ​​corresponding to all key analysis points are sorted in ascending order, and according to the sorting results, a high quantile flow rate value, a high quantile temperature value, a high quantile pressure value and a high quantile stress value are determined; Determining an external comprehensive influencing factor according to the high quantile flow velocity value, the high quantile temperature value, the high quantile pressure value and the high quantile stress value; The material characteristic factors and the external comprehensive influencing factors are analyzed to determine a comprehensive potential risk value, and the comprehensive potential risk value, the material characteristic factors and the external comprehensive influencing factors are determined as the potential risk information of the seal.

2. The method according to claim 1, characterized in that Based on the seal contact surface, the mold model and the relative distance, according to the flow velocity influence lower limit, the pressure influence lower limit, the temperature influence lower limit and the stress influence lower limit, the fluid flow velocity value, the temperature value, the pressure value and the stress value corresponding to each analysis point are analyzed to determine a set of key analysis points, which is specifically the following formula: R ={ I ∈ M}∨{ I ∈ Ω ∧ d I ＜ D | V I ≥ V n ∨ P I ≥ P n ∨ T I ≥ T n ∨ σ I ≥ σ n}； in, R is the set of key analysis points, I is the current analysis point, M is the seal contact surface, Ω is the mold model geometry, d I is the relative distance between the current analysis point and the contact surface of the seal, D is the preset distance threshold, V I is the fluid velocity value corresponding to the current analysis point, V n is the lower limit of the flow velocity, P I is the pressure value corresponding to the current analysis point, P n is the lower limit of the pressure influence, T I is the temperature value corresponding to the current analysis point, T n is the lower limit of the temperature influence, σ I is the stress value corresponding to the current analysis point, σ n is the lower limit of the stress influence.

3. The method according to claim 1, characterized in that The material characteristic factor and the external comprehensive influencing factor are analyzed to determine the comprehensive potential risk value, which is specifically the following formula: ； in, G is the comprehensive potential risk value, A is the preset strength relationship coefficient, B To preset the intensity influence adjustment index, S is the tensile strength of the material, f is the preset temperature response index, L is the preset temperature influence coefficient, E is the thermal expansion coefficient, is the material characteristic factor, H is the external comprehensive influencing factor.

4. The method according to claim 1, characterized in that: The external comprehensive influencing factor is determined according to the high quantile flow rate value, the high quantile temperature value, the high quantile pressure value and the high quantile stress value, which is specifically the following formula: ； in, H is the external comprehensive influencing factor, V is the high percentile flow rate value, α is the preset flow rate influence condition coefficient, β The preset temperature affects the adjustment index. T is the high percentile temperature value, T 0 is the preset reference temperature value, P is the high percentile pressure value, C is the preset pressure threshold, σ is the high quantile stress value, σ 0 is the default stress reference.

5. The method according to claim 1, characterized in that According to the potential risk information of the seal, the risk report and suggestion information are determined and output, including: Comparing the comprehensive potential risk value in the potential risk information with a preset risk threshold to determine whether the comprehensive potential risk value exceeds the preset risk threshold; If the comprehensive potential risk value exceeds the preset risk threshold, analyzing and determining the influence ratio of the material characteristic factor and the external comprehensive influencing factor on the comprehensive potential risk value; If the influence ratio of the material characteristic factor is greater than the influence ratio of the external comprehensive influencing factor, the seal material re-evaluation requirement is output as the recommendation information; If the influence ratio of the external comprehensive influencing factors is greater than the influence ratio of the material characteristic factors, the casting process re-evaluation requirement is output as the suggestion information; The risk report is constructed and output based on the potential risk information, the impact ratio of the material characteristic factors and the impact ratio of the external comprehensive influencing factors.

6. The method according to claim 5, characterized in that The method further comprises: Based on the mold data set, according to the vacuum system parameters, the casting conditions and the casting materials, evaluating the mold flying risk and the corresponding flying high-risk area in the demolding stage; The mold flying material risk is compared with a preset flying material risk threshold. If the mold flying material risk exceeds the preset flying material risk threshold, the mold flying material risk is included in the risk report, and the flying material high-risk area is focused on and included in the recommendation information.

7. A casting quality control system based on Magmasoft, characterized in that: Applied to perform the method according to any one of claims 1 to 6, comprising: A casting simulation module, used for acquiring a mold data set and a casting parameter set, simulating a vacuum casting process according to the mold data set and the casting parameter set, and determining a simulation result; A data screening module, used for analyzing the mold data set, screening the simulation results, and determining a key impact data set of the seal; A risk analysis module, used for acquiring a seal parameter set, analyzing the seal key impact data set based on the seal parameter set, and determining potential risk information of the seal; The output module is used to determine and output risk reports and suggestion information based on the potential risk information of the seals.

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