A vibration sand process simulation optimization method, system, equipment and medium

Abstract

The present invention belongs to the technical field of hollow structure casting manufacturing, specifically relating to a sand vibration process simulation optimization method, system, equipment, and medium. The method establishes a basic CAE model based on the original 3D model, determines the excitation point based on the layout of the sand vibration equipment and pouring system, establishes a forced vibration curve based on the vibration process, sets a simulation environment based on the contact between the casting and the sand core, performs simulation analysis of the sand vibration process using computer simulation software, determines the simulation stress threshold based on the strain gauge results during the sand vibration process, calibrates the simulation model, and adjusts the sand vibration parameters based on the above analysis results to optimize the sand vibration process. By establishing an accurate simulation model to simulate the stress conditions of the casting during the sand vibration process, the method achieves optimization of the sand vibration process and early assessment of casting quality.

Description

Technical Field

[0001] The present invention belongs to the technical field of hollow structure casting manufacturing, and in particular relates to a sand vibration process simulation optimization method, system, equipment and medium. Background Art

[0002] The sand vibration process is an indispensable step in the production of one-piece hollow structural castings. Its purpose is to remove the molding sand from the casting through vibration, ensuring the surface quality and internal structural integrity of the casting. However, in the production of hollow structural castings, due to their complex and narrow internal space, molding sand easily remains inside the casting, resulting in a decrease in the casting surface quality, an increase in internal defects, and even affecting the structural strength of the casting. In addition, the traditional sand vibration process mainly relies on experience to adjust the vibration parameters, lacks scientific optimization methods, and is difficult to adapt to the production needs of complex castings. This often leads to problems such as low sand vibration efficiency, increased energy consumption, and unstable casting quality.

[0003] In recent years, the application of computer simulation technology in the foundry industry has become increasingly widespread. The application of simulation technology in the vibrating sand process has shown great potential. By simulating the vibration process and analyzing the sand removal efficiency and the stress conditions on the casting, it is possible to optimize vibration parameters, reduce sand residue, and improve casting quality. This simulation-based optimization method not only effectively addresses failure issues in the vibrating sand process but also reduces resource waste during production and improves production efficiency.

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

[0005] The present invention proposes a sand vibration process simulation optimization method, system, equipment and medium to solve the problem that the existing technology is difficult to predict potential failure points in the sand vibration process and optimize the sand vibration process parameters.

[0006] To achieve the above object, the present invention proposes the following technical solutions:

[0007] A sand vibration process simulation optimization method includes the following steps:

[0008] Step 101: establishing a basic CAE model based on the original 3D model of the target casting;

[0009] Step 102, determining the excitation point based on the arrangement of the sand vibrating equipment and the pouring system;

[0010] Step 103, establishing a forced vibration curve of the casting based on the sand vibration process;

[0011] Step 104, setting a simulation environment based on the contact condition between the casting and the sand core;

[0012] Step 105: Establish a simulation model and perform simulation analysis based on the basic CAE model, the excitation point, the forced vibration curve of the casting, and the simulation environment to obtain simulation analysis results, including the stress change curve and the maximum stress value at the target position of the casting;

[0013] Step 106, determining whether the stress change curve is qualified. If qualified, setting a stress threshold and proceeding to step 107; if unqualified, adjusting the simulation model until the simulation analysis result is qualified;

[0014] 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.

[0015] Preferably, the step 101 specifically includes:

[0016] The original 3D is meshed, including surface elements and solid elements, and the material properties of the casting and the sand core are defined. Based on the surface elements, solid elements and material properties, a basic CAE model is established.

[0017] Preferably, the step 102 is specifically as follows:

[0018] Determine the vibration source and excitation method of the sand vibrating equipment, and determine the location of the excitation point based on the equipment layout and the structure of the pouring system.

[0019] Preferably, in step 103, the process of establishing the forced vibration curve of the casting is specifically as follows:

[0020] The vibration characteristics of the casting structure and sand core components are determined through static analysis. External excitation is applied to the excitation point through dynamic analysis, and the response of the casting under these excitations is calculated to obtain the forced vibration curve of the casting.

[0021] Preferably, the step 104 is specifically as follows:

[0022] Set the contact model between the casting and the sand core to automatic contact;

[0023] Define the friction coefficient to simulate the friction effect between the casting and the sand core during the vibration process;

[0024] Set boundary conditions to simulate the fixed and free boundaries of the vibrating sand environment.

[0025] Preferably, the step 106 is specifically as follows:

[0026] Use strain gauges to record the stress change at the maximum stress position of the target position of the casting during the sand vibration process as the standard stress change;

[0027] If the error between the simulated stress change curve and the standard stress change curve is less than 10%, the process proceeds to step 107; otherwise, the simulation model is adjusted until the error between the simulated stress change curve and the standard stress change curve is less than 10%.

[0028] Preferably, in step 106, the stress value at which a crack appears at a target position of the casting recorded by the strain gauge is used as the stress threshold.

[0029] A vibration sand 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;

[0030] The modeling module is used to establish a basic CAE model based on the original 3D;

[0031] The excitation point arrangement module is used to determine the excitation points based on the arrangement of the sand vibrating equipment and the pouring system;

[0032] The forced vibration curve establishment module is used to establish a forced vibration curve of the casting based on the sand vibration process;

[0033] The simulation environment setting module is used to set the simulation environment based on the contact situation between the casting and the sand core;

[0034] The simulation analysis execution module is used to establish a simulation model and perform simulation analysis based on 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;

[0035] The analysis module is used to determine whether the stress change curve is qualified. If qualified, a signal is sent to the calibration module; if unqualified, the simulation model is adjusted until the simulation analysis result is qualified.

[0036] 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; if not, 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.

[0037] An electronic device comprising a memory and a processor;

[0038] memory for storing computer programs;

[0039] The processor is used to execute the computer program, and when the computer program is executed by the processor, the steps of the vibration sand process simulation optimization method are implemented.

[0040] A computer-readable storage medium stores a computer program, which, when executed by a processor, implements the steps of a vibration sand process simulation optimization method.

[0041] The present invention is beneficial in that:

[0042] This paper proposes a sand vibration process simulation optimization method. This method establishes a basic CAE model based on the original 3D model, determines the excitation point based on the layout of the sand vibration equipment and gating system, establishes a forced vibration curve based on the vibration process, and sets the simulation environment based on the contact between the casting and the sand core. By simulating the physical phenomena during the sand vibration process, this method optimizes the sand vibration parameters to improve sand vibration efficiency and casting quality, while reducing production costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0043] The accompanying drawings, which constitute part of the present invention, are intended to provide a further understanding of the present invention. The exemplary embodiments of the present invention and their descriptions are intended to explain the present invention and do not constitute an undue limitation of the present invention. In the accompanying drawings:

[0044] Figure 1 This is a flow chart of a vibration sand process simulation optimization method;

[0045] Figure 2 Create a CAE model for a casting product based on vibration sand simulation;

[0046] Figure 3 Schematic diagram of crack locations after sand vibrating process for a casting product;

[0047] Figure 4 A schematic diagram of the stress weak location of a casting product obtained by performing a simulation analysis of the sand vibration process using computer simulation software;

[0048] Figure 5 The stress weak position of a casting product when the vibration frequency is 20HZ, and the stress value is less than the threshold;

[0049] Figure 6 Schematic diagram of an electronic device. DETAILED DESCRIPTION

[0050] The present invention will be described in detail below with reference to the accompanying drawings and in combination with embodiments. It should be noted that, in the absence of conflict, the embodiments and features of the embodiments of the present invention can be combined with each other.

[0051] The following detailed description is an exemplary description and is intended to provide further detailed description of the present invention. Unless otherwise indicated, all technical terms used in the present invention have the same meaning as those generally understood by those skilled in the art to which the present invention belongs. The terms used in the present invention are only for describing specific embodiments and are not intended to limit the exemplary embodiments according to the present invention. Example 1:

[0052] See also Figure 1 As shown, the present invention provides a vibration sand process simulation optimization method, which specifically includes the following steps:

[0053] Step 101: Based on the original 3D model of the target casting, a basic CAE model is established according to the knowledge related to finite element analysis. Specifically,

[0054] First, meshing is completed, including surface elements and solid elements. The mesh size is set to 4 mm, the surface element type is set to M3D6, and the solid element type is set to C3D10M. Then, material properties are defined for the casting and sand core, including density, elastic modulus, Poisson's ratio, etc., to ensure the accuracy of the simulation results.

[0055] In this embodiment, the CAE model is as follows Figure 2 As shown in the figure, the yellow circle on the gating system is the determined excitation point position, and the red triangle pattern is the constraint point in the model.

[0056] Step 102: Determine the excitation point based on the arrangement of the sand vibrating equipment and the pouring system; specifically:

[0057] The working principle and dynamic characteristics of the sand vibration equipment are analyzed to determine the vibration source and excitation method of the sand vibration equipment. In this embodiment, the vibration wave of the casting site equipment is a sine wave, and 6 excitation hammers are excited along the Z direction.

[0058] According to the equipment layout and the structure of the casting system, such as the sprue, runner and ingates, the positions of the six vibration excitation points are determined. The selection rule is that these points can effectively cover the entire casting without causing local over-vibration.

[0059] Step 103: Establishing a forced vibration curve of the casting based on the sand vibration process; specifically:

[0060] Establish forced vibration curve, set parameters such as vibration frequency, amplitude, vibration direction, etc., and simulate the working principle of sand vibration equipment;

[0061] The process of setting up the forced vibration related steps is 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.

[0062] The static analysis step specifically involves performing a modal analysis to determine the vibration characteristics of the casting structure and sand core components, including the natural frequency and mode shape. The dynamic analysis step specifically involves applying external excitations, such as periodic forces or displacements, to the excitation points and calculating the casting's response under these excitations to obtain results such as frequency response curves and vibration amplitudes.

[0063] Step 104: Setting a simulation environment based on the contact between the casting and the sand core; specifically:

[0064] Set the contact conditions during the sand vibration process, that is, the contact model between the casting and the sand core. The contact model adopts "automatic contact" and automatically identifies and creates contact pairs through software settings; define the friction coefficient to simulate the friction effect between the casting and the sand core during the sand vibration process; set the boundary conditions to simulate the fixed and free boundaries of the sand vibration environment.

[0065] Step 105: Perform simulation analysis of the sand vibration process based on computer simulation software; specifically:

[0066] The constructed simulation model is submitted for calculation and the simulation results are output; the output results are imported into HyperGraph software to output the stress conditions of the casting during forced vibration, namely the displacement change curve of the weak position over time and the stress change curve.

[0067] The simulation results of this embodiment are as follows Figure 3 、 4 As shown in the figure, the location of the vibration sand crack is consistent with the stress weak location obtained by simulation.

[0068] Step 106, determining the simulation stress threshold based on the strain gauge results during the sand vibration process, and calibrating the simulation model; specifically:

[0069] Select 3-5 locations with the maximum stress values ​​and attach strain gauges to record the stress changes during the sand vibration process.

[0070] The recorded stress value is compared with the simulation result. If the error between the two is greater than 10%, the process returns to step 105 and adjusts the simulation model, including the boundary conditions, material parameters, mesh size, etc., until the error between the stress value analyzed by simulation and the stress value collected by strain gauge is less than 10%.

[0071] The process is shown in Table 1:

[0072] Table 1. The process of determining the simulated stress threshold of a casting product based on the strain gauge results during the sand vibration process

[0073]

[0074] The stress value when cracks appear in the casting is recorded and used as the threshold.

[0075] Step 107, based on the above analysis results, adjust the vibration parameters to optimize the vibration process; specifically:

[0076] Based on the stress results, the threshold in step 106 is compared. If the stress value is less than the threshold, the optimization is completed. If the stress value is greater than the threshold, the vibration parameters, such as the vibration frequency and the number of excitation points, are adjusted, and steps 103-105 are repeated to optimize the vibration process until the maximum stress value at the target position of the casting is less than the threshold.

[0077] In this embodiment, when the vibration frequency of a casting product is 20HZ, the stress weak position is as follows Figure 5 As shown, the stress value is smaller than the threshold.

[0078] This method establishes a basic CAE model based on the original 3D model, determines the excitation point based on the layout of the sand vibrating equipment and pouring system, establishes a forced vibration curve based on the vibration process, sets up a simulation environment based on the contact between the casting and the sand core, performs simulation analysis of the sand vibrating process using computer simulation software, determines the simulated stress threshold based on strain gauge results during the sand vibrating process, calibrates the simulation model, and adjusts the sand vibrating parameters based on these analysis results to optimize the sand vibrating process. By establishing a precise simulation model that simulates the stress conditions on the casting during the sand vibrating process, this method optimizes the sand vibrating process and pre-evaluates the casting quality.

[0079] The vibration sand process simulation 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.

[0080] Example 2:

[0081] The present invention provides a vibration sand process simulation optimization system, which specifically 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.

[0082] The modeling module is used to establish a basic CAE model based on the original 3D according to finite element related knowledge.

[0083] The excitation point arrangement module is used to determine the excitation points based on the arrangement of the sand vibrating equipment and the pouring system.

[0084] The forced vibration curve establishing module is used to establish a forced vibration curve of a casting based on a sand vibration process.

[0085] The simulation environment setting module is used to set the simulation environment based on the contact situation between the casting and the sand core.

[0086] The simulation analysis execution module is used to perform simulation analysis of the sand vibration process based on computer simulation software.

[0087] The analysis module is used to perform simulation analysis of the sand vibration process based on computer simulation software.

[0088] The calibration module is used to adjust the vibration parameters and optimize the vibration process based on the analysis results of the analysis module, repeat the operation process 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, and output the result.

[0089] Example 3:

[0090] See also Figure 6 As shown, the present invention further 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.

[0091] The memory 101 can be used to store the computer program 103. The processor 102 implements the steps of the vibration sand process simulation optimization method described in Example 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 can mainly include a program storage area and a data storage area. The program storage area can store an operating system and at least one application required for a function (such as a sound playback function, an image playback function, etc.); the data storage area can store data (such as audio data) created based on the use of the electronic device 100. In addition, the memory 101 can include a 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 disk storage device, a flash memory device, or other non-volatile solid-state storage device.

[0092] The at least one processor 102 may be a central processing unit (CPU), or other general-purpose processors, digital signal processors (DSP), application-specific integrated circuits (ASIC), field-programmable gate arrays (FPGA), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc. The processor 102 may be a microprocessor or 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 using various interfaces and lines.

[0093] The memory 101 in the electronic device 100 stores a plurality of instructions to implement a vibration sand process simulation optimization method, and the processor 102 can execute the plurality of instructions to achieve the method.

[0094] Example 4:

[0095] If the module / unit integrated in the electronic device 100 is implemented in the form of a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the present invention implements all or part of the process in the above-mentioned embodiment method, and can also be completed by instructing the relevant hardware through a computer program. The computer program can be stored in a computer-readable storage medium, and the computer program can implement the steps of the above-mentioned method embodiments when executed by the processor. Among them, the computer program includes computer program code, and the computer program code can be in source code form, object code form, executable file or some intermediate form, etc. The computer-readable medium may include: any entity or device that can carry the computer program code, recording medium, U disk, mobile hard disk, magnetic disk, optical disk, computer memory and read-only memory (ROM, Read-Only Memory).

[0096] It is understood from common technical knowledge that the present invention may be implemented by other embodiments that do not depart from its spirit or essential features. Therefore, the embodiments disclosed above are, in all respects, merely illustrative and not exclusive. All modifications within the scope of the present invention or equivalent to the scope of the present invention are intended to be encompassed by the present invention.

[0097] Those skilled in the art will appreciate that embodiments of the present invention may be provided as methods, systems, or computer program products. Thus, the present invention may take the form of an entirely hardware embodiment, an entirely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, the present invention may take the form of a computer program product implemented on one or more computer-usable storage media (including but not limited to magnetic disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0098] The present invention is described with reference to flowcharts and / or block diagrams of methods, devices (systems), and computer program products according to embodiments of the present invention. It should be understood that each process and / or block in the flowcharts and / or block diagrams, as well as combinations of processes and / or blocks in the flowcharts and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, a special-purpose computer, an embedded processor, or other programmable data processing device to produce a machine, so that the instructions executed by the processor of the computer or other programmable data processing device generate instructions for implementing the processes in the flowcharts and / or block diagrams. Figure 1 a process or multiple processes and / or boxes Figure 1 A device that provides the functions specified in a block or multiple blocks.

[0099] These computer program instructions may also be stored in a computer readable memory that can direct a computer or other programmable data processing device to work in a specific manner, so that the instructions stored in the computer readable memory produce an article of manufacture comprising an instruction device, which implements the process Figure 1 a process or multiple processes and / or boxes Figure 1 The function specified in one or more boxes.

[0100] These computer program instructions can also be loaded onto a computer or other programmable data processing device so that a series of operational steps are executed on the computer or other programmable device to produce a computer-implemented process, thereby providing the instructions executed on the computer or other programmable device for implementing the process. Figure 1 a process or multiple processes and / or boxes Figure 1 A step that specifies a function in one or more boxes.

[0101] 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 it. Although the present invention has been described in detail with reference to the above embodiments, ordinary technicians in the field should understand that the specific implementation methods of the present invention can still be modified or replaced by equivalents. Any modification or equivalent replacement that does not depart from the spirit and scope of the present invention should be covered by the scope of protection of the claims of the present invention.

Claims

1. A vibration sand process simulation optimization method, characterized in that: The steps include: Step 101: establishing a basic CAE model based on the original 3D model of the target casting; Step 102, determining the excitation point based on the arrangement of the sand vibrating equipment and the pouring system; Step 103, establishing a forced vibration curve of the casting based on the sand vibration process; Step 104, setting a simulation environment based on the contact condition between the casting and the sand core; Step 105: Establish a simulation model and perform simulation analysis based on the basic CAE model, the excitation point, the forced vibration curve of the casting, and the simulation environment to obtain simulation analysis results, including the stress change curve and the maximum stress value at the target position of the casting; Step 106, determining whether the stress change curve is qualified. If qualified, setting a stress threshold and proceeding to step 107; if unqualified, adjusting 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; 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. A vibration sand process simulation optimization method according to claim 1, characterized in that: The step 101 specifically includes: The original 3D is meshed, including surface elements and solid elements, and the material properties of the casting and the sand core are defined. Based on the surface elements, solid elements and material properties, a basic CAE model is established.

3. A vibration sand process simulation optimization method according to claim 2, characterized in that: The step 102 is specifically as follows: Determine the vibration source and excitation method of the sand vibrating equipment, and determine the location of the excitation point based on the equipment layout and the structure of the pouring system.

4. The sand vibration process simulation optimization method according to claim 1, characterized in that: In step 103, the process of establishing the forced vibration curve of the casting is specifically as follows: The vibration characteristics of the casting structure and sand core components are determined through static analysis. External excitation is applied to the excitation point through dynamic analysis, and the response of the casting under these excitations is calculated to obtain the forced vibration curve of the casting.

5. The sand vibration process simulation optimization method according to claim 1, characterized in that: The step 104 is specifically as follows: Set the contact model between the casting and the sand core to automatic contact; Define the friction coefficient to simulate the friction effect between the casting and the sand core during the vibration process; Set boundary conditions to simulate the fixed and free boundaries of the vibrating sand environment.

6. The sand vibration process simulation optimization method according to claim 1, characterized in that: The step 106 is specifically as follows: Use strain gauges to record the stress change at the maximum stress position of the target position of the casting during the sand vibration process as the standard stress change; If the error between the simulated stress change curve and the standard stress change curve is less than 10%, the process proceeds to step 107; otherwise, the simulation model is adjusted until the error between the simulated stress change curve and the standard stress change curve is less than 10%.

7. A vibration sand process simulation optimization method according to claim 6, characterized in that: In step 106, the stress value at which cracks appear at the target position of the casting recorded by the strain gauge is used as the stress threshold.

8. A vibration sand process simulation optimization system, characterized in that: It includes modeling module, excitation point arrangement module, forced vibration curve establishment module, simulation environment setting module, simulation analysis execution module, analysis module and 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 vibrating equipment and the pouring system; The forced vibration curve establishment module is used to establish a forced vibration curve of the casting based on the sand vibration process; The simulation environment setting module is used to set the simulation environment based on the contact situation between the casting and the sand core; The simulation analysis is used to establish a simulation model and perform simulation analysis based on the basic CAE model, excitation points, forced vibration curve of the casting 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 qualified, a signal is sent to the calibration module; if unqualified, 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; if not, 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.

9. An electronic device, characterized in that: including memory and processor; memory for storing computer programs; A processor is used to execute the computer program, and when the computer program is executed by the processor, the steps of the vibration sand process simulation optimization method according to 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, and when the computer program is executed by the processor, the steps of the vibration sand process simulation optimization method according to any one of claims 1 to 7 are implemented.

Images