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<p>As a critical component in tunnel excavation, the TBM cutter ring demands efficient fabrication and superior strength and toughness. This study focuses on the centrifugal casting process within the short process for manufacturing the cutter ring, explicitly analyzing the DC53 tube billet casting. The paper investigates and analyzes the centrifugal casting metal liquid’s filling flow and solidification crystallization behavior. Utilizing thermal-fluid coupling, the grain growth and defect formation tendencies are analyzed using the CA method and two defect criteria, aligning with the macroscopic solidification morphology observed in actual castings. The findings indicate that the centrifugal flow field’s turbulence originates from the metal stream’s impact on the mold, and the melt temperature tends to be uniform during solidification. The fluctuating flow field and the directional development of the temperature field result in a “sandwich” bidirectional solidification structure of the metal, comprising columnar and equiaxed crystals. The Niyama and dimensionless criteria predict shrinkage positions at 35 pct of the radial thickness, with similar errors in predicting the convective feeding effect in the supergravity field. Additionally, free surface fluctuations lead to wrinkles on the casting’s inner surface, narrowing the margin of the high-speed heat transfer zone compared to the internal low-speed heat transfer zone.</p>

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Filling and Solidification Behavior Simulation of Manufacturing DC53 Cutter Ring Tube Through Centrifugal Casting Process

  • 期刊论文

  • 发表日期：

    2025年2月18日

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  • Longchao Liu,
  • Chongsheng Ma,
  • Yulong Cao,
  • Dong Hou,
  • Shiyi Peng

摘要

As a critical component in tunnel excavation, the TBM cutter ring demands efficient fabrication and superior strength and toughness. This study focuses on the centrifugal casting process within the short process for manufacturing the cutter ring, explicitly analyzing the DC53 tube billet casting. The paper investigates and analyzes the centrifugal casting metal liquid’s filling flow and solidification crystallization behavior. Utilizing thermal-fluid coupling, the grain growth and defect formation tendencies are analyzed using the CA method and two defect criteria, aligning with the macroscopic solidification morphology observed in actual castings. The findings indicate that the centrifugal flow field’s turbulence originates from the metal stream’s impact on the mold, and the melt temperature tends to be uniform during solidification. The fluctuating flow field and the directional development of the temperature field result in a “sandwich” bidirectional solidification structure of the metal, comprising columnar and equiaxed crystals. The Niyama and dimensionless criteria predict shrinkage positions at 35 pct of the radial thickness, with similar errors in predicting the convective feeding effect in the supergravity field. Additionally, free surface fluctuations lead to wrinkles on the casting’s inner surface, narrowing the margin of the high-speed heat transfer zone compared to the internal low-speed heat transfer zone.