316L不銹鋼歧管精密鑄造殼模變形及補償措施的實驗與數值研究;Experimental and Numerical Investigation of Shell Mold Deformation and Compensation Measure in Precision Casting of 316L Stainless Steel Manifold

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题名:	316L不銹鋼歧管精密鑄造殼模變形及補償措施的實驗與數值研究;Experimental and Numerical Investigation of Shell Mold Deformation and Compensation Measure in Precision Casting of 316L Stainless Steel Manifold
作者:	林杰楓;LIN, CHIEH-FONG
贡献者:	機械工程學系
关键词:	精密鑄造;蠟模;變形補償;位移;應力;316L不鏽鋼
日期:	2024-08-14
上传时间:	2024-10-09 17:25:59 (UTC+8)
出版者:	國立中央大學
摘要:	精密鑄造的品質顯著影響其製造成本。在不鏽鋼岐管的製造過程中，鑄件的尺寸精度是評估其品質的重要指標。為了控制精密鑄造過程中鑄件的變形，提出了一種基於反向變形原理的模具改善方法，步驟與方法如下： 1. 首先採用3D掃描技術定量測量蠟模以及相對應的精密鑄造零件的變形情況。 2. 根據反向變形原理，岐管蠟模的長邊(LS)和短邊(SS)部分進行變形補償。LS和SS的補償量分別為1.2mm和1.5mm。 3. 將補償後的蠟模型CAD導入FEM鑄造模擬軟體中，模擬鑄件冷卻後的位移以及方向，同時模擬殼模上的應力分佈。 4. 確認補償蠟模後精密鑄造模擬的尺寸精度在公差範圍內，並對實際蠟模進行修正。 5. 透過實際生產和3D測量技術，驗證零件的尺寸精度保持在±0.3毫米以內。本研究的主要貢獻在於基於數值模擬研究反向變形原理並改善蠟模，透過實驗驗證，鑄件LS的最大偏差量從1.21毫米減小到0.13毫米，降低了89.1%，同時，SS的最大偏差量從1.22毫米減少到0.12毫米，降低了89.7%，尺寸公差控制在±0.3毫米以內。雖然應力所引起的裂縫確實存在並且已經實驗證實，但它們並不影響鑄件的生產品質。最終，所提出的幾何補償蠟模和精密鑄造產品成功完成了試生產，並順利進入到鑄造廠的實際批量生產。 ;The quality of investment casting significantly affects its manufacturing cost. During the manifold manufacturing process, the deformation of the casting is an important indicator for evaluating its quality. To control the deformation of castings during investment casting, a mold improvement method based on the deformation compensation principle is proposed: 1. First, perform 3D scanning technology to quantitatively measure the deformation of the wax model and the corresponding investment casting parts. 2. Based on the reverse deformation principle, perform deformation compensation on the long side (LS) and short side (SS) of the manifold′s wax pattern. The compensation amounts for the LS and SS are 1.5 mm and 1.2 mm, respectively. 3. Import the compensated wax model CAD into FEM software to simulate the displacement of the casting after cooling and simultaneously simulate the stress on the shell mold. 4. Confirm that the dimensional accuracy of the compensated wax model investment casting simulation is within the tolerance range, and make corrections to the actual wax mold. 5. Through actual production and 3D measurement technology, verify that the dimensional accuracy of the parts is maintained within ±0.3 mm. The main contribution of this paper aims to study the reverse deformation principle and improve the mold based on numerical simulation. Through experimental verification, the maximum deformation of the LS was reduced from 1.21 mm to 0.13 mm, a reduction of 89.1%, and the maximum deformation of the SS was reduced from 1.22 mm to 0.12 mm, a reduction of 89.7%, controlling deformation errors within ±0.3 mm. Ultimately, the proposed geometrically compensated wax pattern and investment casted products were successfully accomplished the pilot run and smooth transitions into actual mass production in the casting foundry. In the end, although stress-induced cracks do exist and have been experimentally confirmed, they do not affect the production quality of the castings.
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