Abstract: Aiming at the commonly used “instantaneous filling and temperature uniformity” of assumption conditions in ingots cast forming process,a simulation and optimization analysis method for influence factors of cast forming process was proposed based on orthogonal experimental design,numerical simulation and response surface methodology.By taking 6-ton ingot of Cr5 steel casting process for example,the sample data were obtained through experimental design and numerical simulation methods,and the primary and secondary order of each factors on response index were obtained with range analysis.A response surface modeling method was presented based on bicubic interpolation algorithm,and the regression response surface model of heat transfer coefficients and preheat temperature and response index was established.A local sensitivity analysis method for parameters was constructed based on response surface function to correct the test results.The results showed that the influence of temperature field change of filling process on solidification process should be considered to ensure the accuracy and reliability for influence factors simulation of the cast forming process,and improve the quality of ingot casting.

Key words: cast forming;numerical simulation, design of experiment, bicubic interpolation, response surface methodology, sensitivity analysis

摘要： 针对目前钢锭铸造成形时常用的“瞬时充型、温度均匀”假设条件,提出一种基于正交试验设计、数值模拟及响应面法的铸造成形过程影响因素模拟与优化分析方法。以材料Cr5钢的6t钢锭铸造过程为研究对象,采用试验设计和数值模拟方法获取试验样本数据,运用极差分析得到各因素对响应指标的主次顺序。基于双三次插值算法的响应面建模方法,建立换热系数及预热温度与响应指标的回归响应面模型。基于响应面函数建立了一种对参数进行局部敏感性分析的方法,以修正试验结果。结果表明：为保证铸造成形过程影响因素模拟的精度和可靠性,提高钢锭的铸造质量,应考虑充型过程温度场变化对凝固过程的影响。

关键词: 铸造成形, 数值模拟, 试验设计, 双三次插值, 响应面法, 敏感性分析