锻压技术

电磁搅拌法制备ZL104铝合金半固态坯料过程的数值模拟研究

英文标题：Numerical simulation of the semi-solid ZL104 alloy prepared by electromagnetic stirring process

作者：张晨阳赵升吨王永飞

单位：西安交通大学

关键词：半固态铝合金电磁搅拌数值模拟

分类号：TS914.1+3

出版年,卷(期):页码：2014,39(11):117-124

摘要：

采用 Ansoft和Fluent软件顺序耦合的方法，建立了电磁搅拌法制备ZL104半固态坯料过程中电磁场和流场的三维耦合模型，并利用VOF法模拟电磁搅拌过程中的液穴现象，获得电磁搅拌法制备该合金半固态坯料的合理工艺参数：搅拌电流为55 A，搅拌频率为25 Hz。结果表明：增加搅拌电流，电磁平均力成比例增加，其分布均匀性基本不变;增加搅拌频率，电磁平均力逐渐增加，其分布均匀性变差。随着搅拌强度的增加，自由液面的漩涡深度不断增加，在强电磁搅拌情况下，浆料出现紊流现象。实验表明，不同搅拌强度下坯料的液面漩涡情况与数值模拟结果一致，同时其微观组织表明在过强的搅拌强度下ZL104半固态坯料微观组织中确实存在大量孔洞。验证了VOF法模拟电磁搅拌过程中液穴的形成过程的可行性及实用性。

Based on sequential coupling method in Ansoft and Fluent softwares, a 3D coupled model of the electromagnetic field and flow field was established in the process of semi-solid ZL104 alloy prepared by electromagnetic stirring(EMS) process. The cavitation in the process of EMS was simulated by VOF method, and reasonable process parameters of semi-solid ZL104 alloy prepared by EMS were obtained. The stirring current was 55 A and the stirring frequency was 25 Hz. The results show that when the stirring current increases, the average electromagnetic force increases proportionally, and its uniformity are almost invariant. However, when the stirring frequency increases, the average electromagnetic force increases gradually, which affects the even distribution. With the increase of stirring intensity, the depth of vortex on the free surface increases accordingly and the turbulent flow is generated under the strong stirring. Experimental results show that the surface vortex under different stirring intensity is consistent with the results of numerical simulation. Semi-solid ZL104 microstructure shows that there are lots of holes under the strong stirring intensity, which verifies the validity and reliability of VOF method applied to simulate the formation of cavitation during the EMS process.

基金项目：

国家自然科学基金资助项目（51335009）；国家04重大科技专项（2011ZX04016-081）；陕西省自然科学基础研究计划项目（2012JQ7032）

张晨阳（1987-），男，博士研究生

参考文献：

［1］Fan Z. Semisolid metal processing [J]. Int. Mater. Rev., 2002, 47: 49-85.
［2］Flemings M C. Behavior of metal alloys in the semisolid state[J]. Metallur. Tran. A, 1991, 22A: 957-981.
［3］Young R P, Riek R G, Flemings M C. Structure and properties of thixocast steel[J]. Metals Technology, 1979, 6(4): 130-137.
［4］Li J Y, Sugiyama S, Yanagimoto J. Microstructural evolution and flow stress of semi-solid type 304 stainless steel [J]. J. of Mater. Process. Technol., 2005, 161: 396-406.
［5］攀刚.低过热度浇注弱电磁搅拌制备半固态Al_30%Si浆料的工艺与理论研究[D]．昆明：昆明理工大学，2007.Pan G．Technical and Theoretical Research of Simi-solid Al-30% Si Slurry Prepared by Low Superheat Pouring Low Intensity Electromagnetic Stirring[D]．Kunming：Kunming University of Science and Technology, 2007.
［6］吴树森，赵君文，万里，等．高能超声波制备铝合金半固态浆料技术的研究[J]．特种铸造及有色合金，2009，29（1）：1-5．Wu S S, Zhao J W, Wan L, et al. Research on technology of preparation of semisolid slurry of aluminum alloy by ultrasonic vibration[J]．Special Casting & Nonferrous Alloys, 2009，29（1）：1-5．
［7］赵君问，吴树森．机械振动制备ZL101铝合金半固态浆料的工艺优化[J]．铸造，2010，59（5）：438-440．Zhao J W，Wu S S. Technological optimization of preparing ZL101 aluminum alloy semi-solid slurry by mechanical vibration[J]．Foundry, 2010，59（5）：438-440．
［8］Martinez R A. A New Technique for the Formation of Semi-solid Structures [D]. Cambridge： Massachusetts Institute of Technology, 2001.
［9］毛卫民．金属半固态成形技术[M]．北京：机械工业出版社，2004.Mao W M．The Metal Semi-solid Forming Technology[M]．Beijing：China Machine Press，2004.
［10］王玉陶，游晓红．电磁搅拌制备半固态浆料的研究及应用现状[J]．山西科技，2008, (1): 148-149.Wang Y T, You X H. The research and application status of semi-solid slurry prepared by electromagnetic stirring[J]．Shanxi Science and Technology，2008, (1): 148-149.
［11］Winter J, Dantziz J A, Tyler D E. Process and apparatus for making thixotropic metal slurries: US Patent, No 4434837
［P］.1984.
［12］Vanluu Dao, Shengdun Zhao, Wenjie Lin. Numerical and experimental study on effect of process parameters on preparation of A356 aluminum alloy semi-solid slurry by electromagnetic stirring[J]. International Journal of Applied Electromagnetics and Mechanics, 2013, 41(2): 153-165.
［13］Zhang Z F, Chen X R, Xu J. Numerical simulation on electromagnetic field, flow field and temperature field in semisolid slurry preparation by A-EMS[J]. Rare Metals, 2010, 29: 635-641.
［14］王承志，刘凤国，袁晓光. 半固态浆料制备过程的电磁－热－流体数值模拟[J]. 沈阳工业大学学报，2010，32（3）：279-285.Wang C Z, Liu F G, Yuan X G. Numerical simulation of electromagnetic thermal and fluid flow field during the semi-solid slurry preparation process[J]. Journal of Shenyang University of Technology，2010，32（3）：279-285.
［15］陈兴润，张志峰，徐骏,等. 电磁搅拌法制备半固态浆料过程电磁场、流场和温度场的数值模拟[J]. 中国有色金属学报，2010，20（5）：937-945.Chen X R, Zhang Z F, Xu J, et al. Numerical simulation of electromagnetic field, flow field and temperature field in semi-solid slurry preparation by electromagnetic stirring[J]. The Chinese Journal of Nonferrous Metals, 2010，20（5）：937-945.

服务与反馈：

【本网站尚未开通全文下载服务】【加入收藏】