Abstract
A reasonable ultrasonic vibration network can improve the casting quality of aluminum alloy. Ultrasonic vibration network based on a honeycomb structure has been designed, referred to as a new vibration network. The new vibration network can solve the problems of nonuniform distribution of power ultrasonic wave, small working area and low volume of ultrasonic vibration network, low efficiency of the frequency spectrum and power spectrum, and poor quality of aluminum alloy casting. The number of vibration nodes can be determined based on the number of layers of the vibration source nodes. The edge length of regular hexagonal honeycomb cells can be determined based on the size of the casting ingot. The output power and resonant frequency of the ultrasonic vibration network can be adjusted in real time according to the status of aluminum alloy melt. A seven-node new ultrasonic network and a four-node ultrasonic network with a traditional structure were selected and used in the experiment and simulation of a 500 mm diameter 2219 aluminum alloy ingot. In comparison with the traditional four-node ultrasonic network, the effective volume and area, frequency spectrum efficiency, and comprehensive coverage probability of the seven-node new ultrasonic vibration network increased by 34.06%, 23.12%, 17.25%, and 0.308, respectively. The difference between the desired value and average efficiency of the power spectrum was 0.292 W/cm2, and the average grain size of aluminum alloy decreased by 34.98 microns. These results indicate that the efficiency of ultrasonic-vibration-assisted casting system and the quality of aluminum alloy casting can be improved using the new ultrasonic vibration network.
Highlights
A suitable structure of an ultrasonic vibration network is beneficial for improving the spatial efficiency of an ultrasonic-vibration-assisted casting system
A reasonable structure of an ultrasonic vibration network ensures a uniform grain size of aluminum alloy melt, considerably reduces the probability of void formation, and stabilizes the output power and harmonic frequency. erefore, building a scientific ultrasonic vibration network and improving the efficiency of ultrasonic-vibration-assisted casting system has attracted a considerable amount of research focus in the field of aluminum alloy casting [1,2,3,4,5]
In the traditional ultrasonic-vibration-assisted casting process, the tool heads of the ultrasonic vibration network are not dependent on each other. e four-node ultrasonic vibration network is basically used in the ultrasonic-vibration-assisted casting process of aluminum alloy ingots with diameters less than
Summary
A suitable structure of an ultrasonic vibration network is beneficial for improving the spatial efficiency of an ultrasonic-vibration-assisted casting system. In the traditional ultrasonic-vibration-assisted casting process of 2219 aluminum alloy ingot with a diameter of 630 mm, the four-node ultrasonic vibration network is adopted. E output power and harmonic frequency of the traditional ultrasonic vibration network are not adjusted in real time in accordance with the situation. E output power and harmonic frequency of the ultrasonic vibration network are adjusted in real time depending on the actual situation. E output power and frequency are stable, the high temperature and high pressure caused by power ultrasonic wave are constant [13,14,15,16], the grain size of the aluminum alloy is uniform [17,18,19], and the working efficiency of the ultrasonic-vibration-assisted casting system and the casting quality are improved E efficiency of the casting network is considerably improved using a hexagonal symmetry mechanism. e output power and harmonic frequency of the ultrasonic vibration network are adjusted in real time depending on the actual situation. e output power and frequency are stable, the high temperature and high pressure caused by power ultrasonic wave are constant [13,14,15,16], the grain size of the aluminum alloy is uniform [17,18,19], and the working efficiency of the ultrasonic-vibration-assisted casting system and the casting quality are improved
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