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中国物理学会期刊

基于机器学习的铸件凝固过程动态收缩行为

CSTR: 32037.14.aps.74.20241581

Machine learning-based study of dynamic shrinkage behavior during solidification of castings

CSTR: 32037.14.aps.74.20241581
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  • 合金凝固过程中的收缩行为是决定铸锭质量的关键因素之一, 利用数值模拟方法可以预测铸锭缩孔. 本文建立了一种基于机器学习的动网格模型, 能够模拟铸件凝固过程的动态收缩行为. 采用元胞自动机进行铸件凝固模拟, 采用径向基函数算法(radial basis function, RBF)和支持向量机算法(support vector machines, SVM)计算凝固收缩过程的网格运动位移, 从而对凝固过程收缩的动态模拟. 采用该模型计算了Al-4.7%Cu合金铸锭的缩孔形貌, 并进行了对应的浇铸实验验证, 模拟结果与实验结果的误差不超过2%, 符合较好. 说明该模型能够有效捕捉凝固收缩引起的铸件变形的动态过程, 且能够捕捉固液界面复杂形貌的演变, 为凝固过程数值模拟提供了一种新思路.

     

    Shrinkage cavities and porosity are the main defects generated in the solidification process of castings. These defects are caused by the alloy’s contraction during solidification, with the final solidified area not being effectively compensated for by the liquid metal, resulting in cavitation defects. Shrinkage cavities and porosity significantly reduce the mechanical properties of castings and shorten their service lives, thus necessitating appropriate process to eliminate them. Utilizing numerical simulation technology can effectively predict the shrinkage of castings during solidification and optimize the process based on simulation results, thereby reducing the occurrence of shrinkage defects, which is a low-cost and high-efficiency method. In this work, a machine learning-driven dynamic mesh model is established to simulate the dynamic shrinkage behavior of castings during solidification. Cellular automata are used to simulate the solidification process of castings, dynamically marking the displacement of boundary points and calculating the displacement of other grids using RBF neural network algorithms and support vector machine algorithms, thereby achieving the dynamic simulation of the solidification process. The model is used to simulate the shrinkage cavity morphology of the Al-4.7%Cu alloy solidification process, and corresponding casting experiments are designed for verification. Comparisons between simulation results and experimental results indicate that this coupled method can effectively capture the casting deformation caused by solidification shrinkage, the evolution of complex solid-liquid interface morphologies, and the deformation of internal grids within the castings. Compared with the experimental results, the simulation results have an error of no more than 2%, providing a new approach for numerically simulating the solidification process.

     

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