Deformation often appears in castings during casting and heat treatment processes, which determines the machining allowance setting and the machining size distribution of product. The paper presents a novel method for integrated simulation of the deformation behavior of castings during casting and heat treatment processes with a unified finite element model. Firstly, analyze the deformation of castings during casting process with the model containing mold and casting, and update the geometry of casting after casting process, then analyze the deformation of castings during heat treatment process and the final geometry shape of casting before machining could be obtained. By the method, investigation on the deformation behavior of a hydro turbine blade casting during casting and heat treatment processes was carried out, and the residual stress distribution and geometry shape of the casting were obtained.
Blades are key part of hydro turbines, which often distorts during heat treatment process for their special structures. In this paper, thermal fluid finite element simulation of the forced air cooling process of a blade casting was carried out under a variety of distances between fans and blades, air speeds, groups of fans and circumstance temperatures. The temperature fields of blade castings were obtained. A novel parameter, temperature difference between surfaces of castings along thickness direction, was proposed to analyze the distortion of blade castings. The distortion behavior of blade castings with martensitic stainless steel were discussed, which is in good agreement with distortion regularity of the experimental ones. The temperature differences between blade casting surfaces are always greater than zero, resulting in distortion which could be divided into three stages. Finally, we focused on discussing the control methods of distortion behavior of blade castings which could be operated in actual production.
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