Sand vibration process simulation optimization method, system, equipment and medium

Abstract

The invention belongs to the technical field of hollow structure casting manufacturing, and particularly relates to a sand vibration process simulation optimization method, system and equipment and a medium. The method comprises the steps of establishing a basic CAE model based on original 3D, determining an excitation point based on arrangement of sand vibration equipment and a pouring system, establishing a forced vibration curve based on a vibration process, setting a simulation environment based on the contact condition of a casting and a sand core, and executing simulation analysis of the sand vibration process based on computer simulation software. And a simulation stress threshold value is determined based on a strain gauge result in the sand vibration process, a simulation model is calibrated, and sand vibration parameters are adjusted based on an analysis result to optimize the sand vibration process. According to the method, an accurate simulation model is established, the stress condition of the casting in the sand vibration process is simulated, and the sand vibration process is optimized and the quality of the casting is evaluated in advance.

Description

Technical Field

[0001] The present invention belongs to the technical field of manufacturing hollow structure castings, and particularly relates to a method, system, device and medium for simulating and optimizing the sand shaking process. Background Art

[0002] The sand shaking process is an indispensable link in the production of integral hollow structure castings. Its purpose is to remove the molding sand in the casting through vibration to ensure the surface quality and internal structure integrity of the casting. However, in the production of hollow structure castings, due to the complex and narrow internal space, the molding sand is likely to remain inside the casting, resulting in a decline in the surface quality of the casting, an increase in internal defects, and even affecting the structural strength of the casting. In addition, the traditional sand shaking process mainly relies on empirical adjustment of vibration parameters, lacking scientific optimization means, and it is difficult to meet the production requirements of complex castings, often leading to problems such as low sand shaking efficiency, increased energy consumption, and unstable casting quality.

[0003] In recent years, the application of computer simulation technology in the casting field has been gradually popularized. The application of simulation technology in the sand shaking process has shown great potential. By simulating the vibration process and analyzing the removal efficiency of the molding sand and the stress situation of the casting, the vibration parameters can be optimized, the residual molding sand can be reduced, and the casting quality can be improved. This simulation-based optimization method can not only effectively solve the failure problems in the sand shaking process but also reduce resource waste in the production process and improve production efficiency.

[0004] Therefore, it is of great practical significance to develop an optimization method based on computer simulation technology for the sand shaking process of hollow structure castings. Summary of the Invention

[0005] The present invention provides a method, system, device and medium for simulating and optimizing the sand shaking process to solve the problems that it is difficult to predict potential failure points and optimize sand shaking process parameters in the existing technology.

[0006] To achieve the above object, the present invention provides the following technical solutions: A method for simulating and optimizing the sand shaking process includes the following steps: Step 101, establishing a basic CAE model based on the original 3D model of the target casting; Step 102, determining the excitation points based on the layout of the sand shaking equipment and the gating system; Step 103, establishing the forced vibration curve of the casting based on the sand shaking process; Step 104, setting the simulation environment based on the contact situation between the casting and the core; Step 105, establishing a simulation model and performing simulation analysis according to the basic CAE model, excitation points, forced vibration curve of the casting and simulation environment, and obtaining the simulation analysis results, including the stress change curve and the maximum stress value at the target position of the casting; Step 106: Determine whether the stress change curve is qualified. If it is qualified, set the stress threshold and proceed to Step 107; if it is unqualified, adjust the simulation model until the simulation analysis result is qualified. Step 107: If the maximum stress value at the target position of the casting is less than the stress threshold, output the result; otherwise, repeat Steps 103 - 105 until the maximum stress value at the target position of the casting is less than the stress threshold.

[0007] Preferably, in Step 101, specifically: Perform mesh division on the original 3D, including surface elements and solid elements, define the material properties of the casting and the core, and establish a basic CAE model based on the surface elements, solid elements, and material properties.

[0008] Preferably, Step 102 is specifically: Determine the vibration source and excitation method of the shakeout equipment, and determine the position of the excitation point according to the equipment layout and the structure of the gating system.

[0009] Preferably, in Step 103, the process of establishing the forced vibration curve of the casting is specifically: Determine the vibration characteristics of the casting structure and the core components through static analysis, apply external excitation to the excitation point through dynamic analysis, and calculate the response of the casting under these excitations to obtain the forced vibration curve of the casting.

[0010] Preferably, Step 104 is specifically: Set the contact model between the casting and the core as automatic contact; Define the friction coefficient to simulate the friction effect between the casting and the core during the shakeout process; Set the boundary conditions to simulate the fixed and free boundaries of the shakeout environment.

[0011] Preferably, Step 106 is specifically: Use strain gauges to record the stress change at the position with the maximum stress value at the target position of the casting during the shakeout process as the standard stress change; If the error between the stress change curve obtained by simulation and the standard stress change is less than 10%, proceed to Step 107; otherwise, adjust the simulation model until the error between the stress change curve obtained by simulation and the standard stress change is less than 10%.

[0012] Preferably, in Step 106, the stress value at which cracks appear at the target position of the casting recorded by the strain gauges is used as the stress threshold.

[0013] A shakeout process simulation optimization system includes a modeling module, an excitation point arrangement module, a forced vibration curve establishment module, a simulation environment setting module, a simulation analysis execution module, an analysis module, and a calibration module; The modeling module is used to establish a basic CAE model based on the original 3D model; The excitation point arrangement module is used to determine the excitation points based on the arrangement of the sand shaking equipment and the gating system; The forced vibration curve establishment module is used to establish the forced vibration curve of the casting based on the sand shaking process; The simulation environment setting module is used to set the simulation environment based on the contact situation between the casting and the core; The simulation analysis execution module is used to establish a simulation model and perform simulation analysis according to the basic CAE model, the excitation points, the forced vibration curve of the casting, and the simulation environment, and obtain the simulation analysis results, including the stress change curve and the maximum stress value at the target position of the casting; The analysis module is used to judge whether the stress change curve is qualified. If it is qualified, a signal is sent to the calibration module; if it is not qualified, the simulation model is adjusted until the simulation analysis results are qualified; The calibration module is used to set the stress threshold. If the maximum stress value at the target position of the casting is less than the stress threshold, the result is output; otherwise, the parameters are modified, and the forced vibration curve establishment module, the simulation environment setting module, and the simulation analysis execution module are repeatedly run until the maximum stress value at the target position of the casting is less than the stress threshold.

[0014] An electronic device includes a memory and a processor; The memory is used to store a computer program; The processor is used to execute the computer program, and when the computer program is executed by the processor, the steps of the sand shaking process simulation optimization method are implemented.

[0015] A computer-readable storage medium stores a computer program, and when the computer program is executed by a processor, the steps of the sand shaking process simulation optimization method are implemented.

[0016] The advantages of the present invention are as follows: The present invention provides a sand shaking process simulation optimization method, which establishes a basic CAE model based on the original 3D model, determines the excitation points based on the arrangement of the sand shaking equipment and the gating system, establishes the forced vibration curve based on the vibration process, and sets the simulation environment based on the contact situation between the casting and the core. The present invention optimizes the sand shaking parameters by simulating the physical phenomena in the sand shaking process, so as to improve the sand shaking efficiency and the quality of the casting and reduce the production cost. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The accompanying drawings forming a part of the present invention are used to provide a further understanding of the present invention. The schematic embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation to the present invention. In the drawings: Figure 1 It is a schematic flow diagram of a vibration sanding process simulation and optimization method; Figure 2 It is a vibration sanding simulation CAE model for a certain casting product; Figure 3 It is a schematic diagram of the crack position after the vibration sanding process is performed on a certain casting product; Figure 4 It is a schematic diagram of the stress weak position obtained from the simulation analysis of the vibration sanding process performed on a certain casting product based on a computer simulation software; Figure 5 It is the stress weak position when the vibration sanding frequency of a certain casting product is 20HZ, and the magnitude of this stress value is less than the threshold; Figure 6 It is a schematic diagram of an electronic device. Specific implementation manners

[0018] The present invention will be described in detail below with reference to the accompanying drawings and in conjunction with embodiments. It should be noted that, without conflict, the embodiments in the present invention and the features in the embodiments can be combined with each other.

[0019] The following detailed descriptions are all exemplary descriptions, aiming to provide further detailed descriptions of the present invention. Unless otherwise specified, all technical terms adopted by the present invention have the same meaning as commonly understood by those of ordinary skill in the technical field to which the present invention belongs. The terms used in the present invention are only for describing specific implementation manners, and are not intended to limit the exemplary embodiments according to the present invention. Embodiment 1:

[0020] Please refer to Figure 1 As shown, the present invention provides a vibration sanding process simulation and optimization method, which specifically includes the following steps: Step 101, based on the relevant knowledge of finite elements, establish a basic CAE model based on the original 3D model of the target casting; specifically: First, complete the mesh division, including surface elements and solid elements. The mesh size is set to 4mm, the surface element type is set to M3D6, and the solid element type is set to C3D10M; then define the material properties for the casting and the sand core, including density, elastic modulus, Poisson's ratio, etc., to ensure the accuracy of the simulation results.

[0021] In this embodiment, the CAE model is as Figure 2 shown. The yellow circle on the gating system in the figure is the determined excitation point position, and the red triangle pattern is the constraint point in the model.

[0022] Step 102, determine the excitation point based on the layout of the vibration sanding equipment and the gating system; specifically: Analyze the working principle and dynamic characteristics of the sand shaking equipment, determine the vibration source and excitation method of the sand shaking equipment. In this embodiment, the vibration wave of the equipment at the casting site is a sine wave, and 6 excitation hammers perform excitation along the Z direction.

[0023] According to the equipment layout and the structure of the gating system, such as the sprue, runner, and ingate, determine the positions of 6 vibration excitation points. The selection rule is that these points can effectively cover the entire casting and do not cause local over-vibration.

[0024] Step 103, establish a forced vibration curve of the casting based on the sand shaking process; specifically: Establish a forced vibration curve, set parameters such as vibration frequency, amplitude, and vibration direction, and simulate the working principle of the sand shaking equipment. Set the relevant steps of forced vibration as follows: Create a forced vibration analysis step in Abaqus, including a static analysis step and a dynamic analysis step, to evaluate the dynamic behavior of the structure in the actual working environment, including displacement, velocity, acceleration, and stress, etc.

[0025] The specific static analysis step is to perform modal analysis to determine the vibration characteristics of the casting structure and the core components, including natural frequency and vibration mode; the specific dynamic analysis step is to apply external excitation to the excitation points, such as periodic force or displacement, and calculate the response of the casting under these excitations to obtain results such as frequency response curve and vibration amplitude.

[0026] Step 104, set the simulation environment based on the contact situation between the casting and the core; specifically: Set the contact conditions during the sand shaking process, that is, the contact model between the casting and the core. The contact model adopts "automatic contact", and through software settings, automatically identify and create contact pairs; define the friction coefficient to simulate the friction effect between the casting and the core during the sand shaking process; set the boundary conditions to simulate the fixed and free boundaries of the sand shaking environment.

[0027] Step 105, perform a simulation analysis of the sand shaking process based on the computer simulation software; specifically: Submit the built simulation model for calculation and output the simulation results; import the output results into HyperGraph software to output the force condition of the casting during forced vibration, that is, the curve of the change of displacement with time and the stress change curve at the weak position.

[0028] The simulation results of this embodiment are as Figure 3 、 4 shown, the position of the sand shaking crack is consistent with the stress weak position obtained from the simulation.

[0029] Step 106, determine the simulation stress threshold based on the strain gauge results during the sand shaking process and calibrate the simulation model; specifically: Select 3 - 5 positions with the largest stress values to attach strain gauges, and record the change of stress during the sand shaking process.

[0030] Compare the recorded stress values with the simulation results. If the error between the two is greater than 10%, return to step 105 and adjust the simulation model. The adjustment content includes boundary conditions, material parameters, mesh size, etc., until the error between the stress value obtained from the simulation analysis and the stress value collected by the strain gauges is less than 10%.

[0031] The process is shown in Table 1: Table 1. Process of determining the simulation stress threshold based on the strain gauge results during the sand shaking process of a certain casting product

[0032] Record the stress value when cracks appear on the casting, and use this stress value as the threshold.

[0033] Step 107, adjust the sand shaking parameters to optimize the sand shaking process based on the above analysis results; specifically: According to the stress results, compare with the threshold in step 106. If the stress value is less than the threshold, the optimization is completed; if the stress value is greater than the threshold, adjust the sand shaking parameters, such as vibration frequency and the number of excitation points, and repeat steps 103 - 105 to optimize the sand shaking process until the maximum stress value at the target position of the casting is less than the threshold.

[0034] In this embodiment, when the sand shaking frequency of a certain casting product is 20HZ, the stress weak position is as Figure 5 shown, and the magnitude of this stress value is less than the threshold.

[0035] The present invention is based on the original 3D to establish a basic CAE model, determine the excitation points based on the layout of the sand shaking equipment and the gating system, establish a forced vibration curve based on the vibration process, set the simulation environment based on the contact situation between the casting and the core, perform a simulation analysis of the sand shaking process based on computer simulation software, determine the simulation stress threshold based on the strain gauge results during the sand shaking process, and calibrate the simulation model. Based on the above analysis results, adjust the sand shaking parameters to optimize the sand shaking process. This method realizes the optimization of the sand shaking process and the early evaluation of the casting quality by establishing an accurate simulation model to simulate the stress condition of the casting during the sand shaking process.

[0036] The sand shaking process simulation and optimization method of the present invention provides an efficient and scientific solution for the production of hollow - structure castings, and has broad application prospects and market value.

[0037] Example 2: The present invention provides a sand shaking process simulation and optimization system, which specifically includes: a modeling module, an excitation point layout module, a forced vibration curve establishment module, a simulation environment setting module, a simulation analysis execution module, an analysis module, and a calibration module.

[0038] The modeling module is used to establish a basic CAE model based on the original 3D according to the finite element related knowledge.

[0039] The excitation point arrangement module is used to determine the excitation points based on the arrangement of the sand vibrating equipment and the gating system.

[0040] The forced vibration curve establishment module is used to establish the forced vibration curve of the casting based on the sand vibrating process.

[0041] The simulation environment setting module is used to set the simulation environment based on the contact situation between the casting and the core.

[0042] The simulation analysis execution module is used to perform the simulation analysis of the sand vibrating process based on the computer simulation software.

[0043] The analysis module is used to perform the simulation analysis of the sand vibrating process based on the computer simulation software.

[0044] The calibration module is used to adjust the sand vibrating parameters to optimize the sand vibrating process based on the analysis results of the analysis module, and repeat the operation processes of the forced vibration curve establishment module, the simulation environment setting module and the simulation analysis execution module until the maximum stress value of the casting is less than the threshold value, and then output the result.

[0045] Embodiment 3: Please refer to Figure 6 As shown, the present invention also provides an electronic device 100; the electronic device 100 includes a memory 101, at least one processor 102, a computer program 103 stored in the memory 101 and executable on the at least one processor 102, and at least one communication bus 104.

[0046] The memory 101 can be used to store the computer program 103. The processor 102 realizes the steps of the method for simulating and optimizing the sand vibrating process described in Embodiment 1 by running or executing the computer program stored in the memory 101 and calling the data stored in the memory 101. The memory 101 may mainly include a program storage area and a data storage area. Among them, the program storage area can store an operating system, application programs required for at least one function (such as a sound playing function, an image playing function, etc.); the data storage area can store data created according to the use of the electronic device 100 (such as audio data, etc.). In addition, the memory 101 may include non-volatile memory, such as a hard disk, a memory, a plug-in hard disk, a smart media card (SMC), a secure digital (SD) card, a flash card, at least one magnetic disk storage device, a flash memory device, or other non-volatile solid state storage devices.

[0047] The at least one processor 102 may be a Central Processing Unit (CPU), or may also be other general-purpose processors, Digital Signal Processors (DSPs), Application Specific Integrated Circuits (ASICs), Field-Programmable Gate Arrays (FPGAs), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc. The processor 102 may be a microprocessor or the processor 102 may also be any conventional processor, etc. The processor 102 is the control center of the electronic device 100, and connects various parts of the entire electronic device 100 through various interfaces and lines.

[0048] The memory 101 in the electronic device 100 stores a plurality of instructions to implement a shakeout process simulation optimization method, and the processor 102 can execute the plurality of instructions to implement it.

[0049] Embodiment 4: If the modules / units integrated in the electronic device 100 are implemented in the form of software functional units and sold or used as independent products, they can be stored in a computer-readable storage medium. Based on this understanding, to implement all or part of the processes in the above embodiment methods of the present invention, it can also be completed by a computer program instructing relevant hardware. The computer program can be stored in a computer-readable storage medium. When the computer program is executed by a processor, the steps of the above various method embodiments can be implemented. Among them, the computer program includes computer program code, and the computer program code can be in the form of source code, object code, executable file, or some intermediate form, etc. The computer-readable medium may include: any entity or device capable of carrying the computer program code, recording medium, USB flash drive, mobile hard disk, magnetic disk, optical disk, computer memory, and read-only memory (ROM, Read-Only Memory).

[0050] As is known by technical common sense, the present invention can be implemented by other embodiments without departing from its spiritual essence or essential features. Therefore, the above-disclosed embodiments are illustrative in all aspects and not exclusive. All changes within the scope of the present invention or within the scope equivalent to the present invention are encompassed by the present invention.

[0051] Those skilled in the art should understand that the embodiments of the present invention can be provided as a method, a system, or a computer program product. Therefore, the present invention can take the form of a complete hardware embodiment, a complete software embodiment, or an embodiment combining software and hardware aspects. Moreover, the present invention can take the form of a computer program product implemented on one or more computer-usable storage media (including but not limited to disk memory, CD-ROM, optical memory, etc.) that contain computer-usable program code.

[0052] The present invention is described with reference to the flowcharts and / or block diagrams of methods, apparatuses (systems), and computer program products according to embodiments of the present invention. It should be understood that each flow and / or block in the flowchart and / or block diagram, as well as the combination of flows and / or blocks in the flowchart and / or block diagram, can be implemented by computer program instructions. These computer program instructions can be provided to the processor of a general-purpose computer, a special-purpose computer, an embedded processor, or other programmable data processing devices to generate a machine, such that the instructions executed by the processor of the computer or other programmable data processing devices produce means for implementing the functions specified in Figure 1 one flow or multiple flows and / or blocks Figure 1 one block or multiple blocks.

[0053] These computer program instructions can also be stored in a computer-readable memory that can direct a computer or other programmable data processing devices to work in a specific manner, such that the instructions stored in the computer-readable memory produce a manufactured article including instruction means that implement the functions specified in Figure 1 one flow or multiple flows and / or blocks Figure 1 one block or multiple blocks.

[0054] These computer program instructions can also be loaded onto a computer or other programmable data processing devices, such that a series of operation steps are executed on the computer or other programmable devices to generate a computer-implemented process. Thus, the instructions executed on the computer or other programmable devices provide steps for implementing the functions specified in Figure 1 one flow or multiple flows and / or blocks Figure 1 one block or multiple blocks.

[0055] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit them. Although the present invention has been described in detail with reference to the above embodiments, those of ordinary skill in the art should understand that: still can modify the specific implementation manners of the present invention or make equivalent replacements. Any modification or equivalent replacement without departing from the spirit and scope of the present invention should be covered by the protection scope of the claims of the present invention.

Claims

1. A simulation optimization method for sand shaking process, characterized in that It includes the following steps: Step 101: Establish a basic CAE model based on the original 3D model of the target casting; Step 102: Determine the excitation points based on the arrangement of the sand shaking equipment and the gating system; Step 103: Establish the forced vibration curve of the casting based on the sand shaking process; Step 104: Set the simulation environment based on the contact situation between the casting and the core; Step 105: According to the basic CAE model, excitation points, the forced vibration curve of the casting, and the simulation environment, establish a simulation model and conduct a simulation analysis to obtain the simulation analysis results, including the stress change curve and the maximum stress value at the target position of the casting; Step 106: Judge whether the stress change curve is qualified. If it is qualified, set the stress threshold and enter Step 107; if it is not qualified, adjust the simulation model until the simulation analysis results are qualified; Step 107: If the maximum stress value at the target position of the casting is less than the stress threshold, output the result; if not, repeat Steps 103 - 105 until the maximum stress value at the target position of the casting is less than the stress threshold; 2. The simulation optimization method for a sand shaking process according to claim 1, characterized in that, Specifically in Step 101: Perform mesh division on the original 3D, including surface elements and solid elements, define the material properties of the casting and the core, and establish a basic CAE model based on the surface elements, solid elements, and material properties.

3. The simulation optimization method of a sand shaking process according to claim 2, characterized in that Specifically in Step 102: Determine the vibration source and excitation method of the sand shaking equipment, and determine the position of the excitation points according to the equipment layout and the structure of the gating system.

4. The simulation optimization method for a sand shaking process according to claim 1, characterized in that, In Step 103, the process of establishing the forced vibration curve of the casting is specifically: Determine the vibration characteristics of the casting structure and the core components through static analysis, apply external excitation to the excitation points through dynamic analysis, and calculate the response of the casting under these excitations to obtain the forced vibration curve of the casting.

5. The simulation optimization method for a sand shaking process according to claim 1, characterized in that, Specifically in Step 104: Set the contact model between the casting and the core as automatic contact; Define the friction coefficient to simulate the friction effect between the casting and the core during the sand shaking process; Set the boundary conditions to simulate the fixed and free boundaries of the sand shaking environment.

6. The simulation optimization method for a sand shaking process according to claim 1, wherein Specifically in Step 106: Use a strain gauge to record the stress change at the position with the maximum stress value at the target position of the casting during the sand shaking process as the standard stress change; If the error between the stress change curve obtained by simulation and the standard stress change is less than 10%, enter Step 107; otherwise, adjust the simulation model until the error between the stress change curve obtained by simulation and the standard stress change is less than 10%.

7. The simulation optimization method of a sand shaking process according to claim 6, wherein, In Step 106, use the stress value at which cracks appear at the target position of the casting recorded by the strain gauge as the stress threshold.

8. A vibration sanding process simulation and optimization system, characterized in that, It includes a modeling module, an excitation point arrangement module, a forced vibration curve establishment module, a simulation environment setting module, a simulation analysis execution module, an analysis module, and a calibration module; The modeling module is used to establish a basic CAE model based on the original 3D; The excitation point arrangement module is used to determine the excitation points based on the arrangement of the sand shaking equipment and the gating system; The forced vibration curve establishment module is used to establish the forced vibration curve of the casting based on the sand shaking process; The simulation environment setting module is used to set the simulation environment based on the contact situation between the casting and the core; The simulation analysis is used to establish a simulation model and conduct simulation analysis according to the basic CAE model, excitation points, casting forced vibration curve, and simulation environment, and obtain simulation analysis results, including the stress change curve and maximum stress value at the target position of the casting; The analysis module is used to determine whether the stress change curve is qualified. If it is qualified, a signal is sent to the calibration module; if it is not qualified, the simulation model is adjusted until the simulation analysis result is qualified; The calibration module is used to set a stress threshold. If the maximum stress value at the target position of the casting is less than the stress threshold, the result is output; otherwise, the parameters are modified, and the forced vibration curve establishment module, simulation environment setting module, and simulation analysis execution module are repeatedly run until the maximum stress value at the target position of the casting is less than the stress threshold; 9. An electronic device, characterized in that, including a memory and a processor; The memory is used to store computer programs; The processor is used to execute the computer program. When the computer program is executed by the processor, the steps of a sand shaking process simulation optimization method as described in any one of claims 1 to 7 are implemented.

10. A computer-readable storage medium, characterized in that the storage medium stores a computer program. When the computer program is executed by a processor, the steps of a sand shaking process simulation optimization method as described in any one of claims 1 to 7 are implemented.

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