电磁无接触成形过程熔体形状的数值模拟及实验研究

Numerical Simulation and Experiment Research on Melt Shape in Electromagnetic Contactless Forming Process

摘要:

应用有限元方法模拟计算了电磁约束成形过程中感应器结构、固／液界面位置、熔体上顶面位置、电流频率及熔体种类对熔体形状的作用规律。结果表明：喇叭形内壁的感应器中熔体可获得侧面基本垂直的理想形状；固／液界面、熔体上顶面位置对熔体形状有明显的影响：电流频率的变化对熔体成形形状的影响很小：在感应器结构、固／液界面及熔体上顶面位置等确定后，合金种类对熔体形状几乎没有影响。同时对电磁成形规律进行了研究，表明实验与模拟计算的结果取得了很好的吻合。用电磁成形方法完成了Al合金、TiAl化合物和Ni基高温合金的无接触成形，制备出了样件，并对组织实现了定向控制。

Abstract:

The effects of inductor structure, the positions of solid/liquid interface and melt top, and different alloys on the melt shape in electromagnetic contactless shaping process have been simulated by FEM method in the present paper. It is found that the inductor with an oblique inside wall makes the melt form an ideal vertical periphery. The position variation of solid/liquid interface and melt top can change the melt shape obviously. The electrical current frequency and the material kind have hardly effects on the melt shape. The experiment results have good agreements with the simulation results. Finally, some bars and plates of Al alloy, TiAl intermetallics and superalloy are produced in an unidirectional control of their structures by the contactless forming process.