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

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