基于配合辊系的楔形板矫直工艺

 采用常规矫直辊系矫直楔形板严重降低了楔形板矫直范围和效率，为了提高楔形板矫直厚度范围和矫直质量，提出了一种基于配合辊系（大直径矫直辊系和小直径矫直辊系）的楔形板矫直方法。首先研究了配合辊系矫直机辊径、辊距与楔形板矫直效果的关系，设计了楔形板矫直机配合辊系，给出了矫直工艺方案；然后给出了配合辊系矫直楔形板的分区原则，基于有限元法建立了基于配合辊系的楔形板矫直过程有限元模型，仿真结果与实测结果一致，验证了有限元模型的正确性；最后对基于配合辊系的楔形板矫直过程进行仿真，计算了常规辊系和配合辊系下楔形板矫直力及残余应力，分析了不同板厚分区对楔形板矫直效果的影响，结果表明，配合辊系设计方案适合楔形板矫直过程且矫直效果较好。     

六斜辊管材矫直过程精度解析

摘要：以管材六斜辊矫直过程为研究对象,推导了管材经一次反弯后,弹复曲率及残余曲率的演变过程。根据管材旋转一圈弯曲2次,计算了管材全流程矫直微元段的反弯次数;借助三次样条函数,以管材与矫直辊接触点为特征点,拟合出了管材在辊系中的弯曲形态。基于所获得的函数,可以获得任意位置处的弯曲曲率;对某一微梁段的反弯弹复过程进行循环迭代,计算出管材微梁段的最终残余曲率,进而得到最终的管材矫后的直线度精度。通过与现场矫直数据对比,证明该模型能够可靠地预测六斜辊矫直精度,为科学合理的设定矫直参数奠定了理论基础。     

六斜辊管材矫直过程精度解析

以管材六斜辊矫直过程为研究对象,推导了管材经一次反弯后,弹复曲率及残余曲率的演变过程。根据管材旋转一圈弯曲2次,计算了管材全流程矫直微元段的反弯次数;借助三次样条函数,以管材与矫直辊接触点为特征点,拟合出了管材在辊系中的弯曲形态。基于所获得的函数,可以获得任意位置处的弯曲曲率;对某一微梁段的反弯弹复过程进行循环迭代,计算出管材微梁段的最终残余曲率,进而得到最终的管材矫后的直线度精度。通过与现场矫直数据对比,证明该模型能够可靠地预测六斜辊矫直精度,为科学合理的设定矫直参数奠定了理论基础。     

Zr-4薄壁管矫直过程VRM20/30矫直机矫直辊角度的调整

探讨了工业生产过程中采用VRM20/30矫直机对Zr-4合金薄壁管矫直时矫直辊的调整方法,并分析研究了矫直辊角度的变化对管材的性能影响。实验证明:矫直辊角度的调整不仅影响管材的表面质量和直线度,而且对管材氢化物取向因子起着非常关键的作用;适当的矫直辊角度能很好的解决管材头尾翘起的问题,获得良好的管材表面和直线度,同时,确保管材的氢化物取向因子控制在理想的范围内。     

矫直辊辊形误差对钢管矫直质量影响的分析

以辊形曲线方程为理论依据利用简化高次方程法计算出理论矫直辊的辊径,使之与实测得到的实际辊径相比较,得出二者的差别,并分析了理论和实际辊形曲线之间的误差对矫直效果的影响,提出了对实际矫直工艺的调整措施。     

辊式矫直过程的接触倾角与曲率耦合分析

研究了在辊式矫直过程中接触倾角与曲率的变化规律,采用曲率积分的方法主要研究了接触倾角、特殊位置与曲率相互耦合关系。结果表明：接触倾角具有累积效应,辊距越大累积效应越突出,减小倾角的措施可以采用增大曲率差商的积分值和减小压下量。大的接触倾角导致大的曲率,曲率的累积效应对残余曲率有负影响,累积效应越大,需采用倾斜量越大。交叉点与接触点对曲率影响很大,交叉点位置比较固定,呈递增趋势,接触点位置和接触倾角成正比。     

矫直辊工艺参数对矫直质量影响的研究与应用

本文对莱钢大H型钢生产线矫直辊R角和装配宽度对矫直质量的影响进行了分析研究,给出了各规格矫直辊装配宽度的理论公式,为生产提供了理论指导,从而提高了矫直质量。     

变辊距矫直的辊距优化设计

对辊距实现优化设计,分别以总矫直力之和矫直力为目标函数,以辊距为设计变量,利用Matlab软件优化设计出辊距相对值,以轧件与辊子间的接触应力为约束条件,进一步获得最佳辊距实际值。在满足矫直要求的前提下,通过变辊距实现了减小矫直力和矫直功的目的,对矫直过程的节能降耗及减小薄壁构件由于矫直力过大产生的矫直缺陷有重要意义。     

大型H型钢水平矫直压下量的优化

在型钢矫直过程中,矫直机各矫直辊压下量直接影响型钢的残余应力及弯曲度,为了减少残余应力及弯曲度,达到国家标准,文章对矫直工艺开展了正交实验仿真,根据实验,得出各工作辊对型钢残余应力和弯曲度的影响,从而找出矫直型钢时压下量的最优方案。     

拉伸弯曲矫直机组设备关键技术研究

研究了拉伸弯曲矫直机的矫直原理，包括带材拉伸弯曲矫直过程中的应力变化和带材弯曲损耗；重点探讨了拉伸弯曲矫直机组设备设计关键技术，包括金属延伸率的确定，带材前后张力的分布，张力辊组与弯曲辊组的辊组布置、参数设计；最后，完成了某厂镀锌机组拉伸弯曲矫直机组设备基本设计。     

辊式矫直过程弹塑性弯曲数学模型

 为了完整和精确地计算辊式矫直过程,根据钢板和矫直机相应的初始条件和边界条件,采用曲率变化量积分的方法,建立了基于Prandtle Reuss增量理论的三维弹塑性弯曲解析数学模型。并分析了厚度08 mm的钢板矫直过程的变形行为,比较了计算曲率和实验曲率,误差在1 mm-1左右。该模型可以精确地计算辊式矫直过程的曲率,预测残余应力和板形,为全面分析辊式矫直过程提供技术支撑,对实际生产具有一定的指导意义。     

冷轧1500mm四辊平整机优化改造实践

针对莱钢冷轧1 500 mm四辊平整机组生产效率低、设备程序不完善、质量控制不稳定等问题,通过增设折叠式导板、增设气动助卷压辊、助卷抱臂增设弧形导板等,对设备进行了改造;对穿带过程、建张模式、平整液控制等程序进行了优化;对标定、温辊及防皱辊、防颤辊的工艺参数以及恒延伸率控制系统等工艺进行完善。改进后平整生产效率提升了35%以上,成材率提高了0.78%,改善了平整带钢的表面质量。     

Curvature and Residual Stress Analysis in Rotational Leveling of Bars

Leveling process plays an important role in delivering the desired material properties and product stand-ards.An analytical method for the rotational leveling process of bars was presented.First,each cross section of the bar in the leveling area was discretized with the roller gap-curvature relations established in both planes XY and XZ. Second,a numerical procedure with two steps was developed to simulate both pressing and leveling processes.This approach can be easily implemented to produce simulation results of the curvature and traj ectory distributions during the leveling process,as well as the bending and residual stresses.It is found that curvature and traj ectory distribu-tions follow a sine-shape due to the characteristic of rotational movement,which also results in a helical pattern of residual stress after leveling.Based on the results obtained,it is also observed that the rotational movement is benefi-cial for adding the number of bending cycle.This is the reason why there are only a few pairs of rollers on the bar leveler.     

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Because roller levelling can remove the flatness defects and induce the residual stress, it is an important step to get qualified plate and sheet. In the levelling parts, the levelling drive system is the deformation energy sources in the levelling process, and presses greater impact on the equipment design and process model. The experimental of characteristics of drive for roller leveling was investigated. The result shows that the biting load is the main reason for roller spindle damage; the fact load is nearly four times as theoretical value. In same time, the result shows that there is a larger inconsistency of the drive toque distribution between the fact load and the theoretical calculation.     

莱钢1500mm冷轧带钢平整轧制工艺实践

介绍了莱钢1 500 mm单机架四辊平整机组的设备组成、控制系统以及平整生产模式。通过对平整延伸率自动控制系统(AEC系统)和分段张力控制系统进行分析,在工艺参数的设置、系统控制的优化、生产模式的选择等方面做到有效控制,从而提高了平整延伸率的控制精度35%,确保了平整后产品力学性能与表面质量的稳定性,产量提高了26%。     

Residual Curvature of Longitudinal Profile Plate Roller in Leveling Process

Roller leveling process of longitudinal profile (LP) plate is hardly studied because plate thickness changes. Deformation characteristics and residual curvature during LP plate leveling process were investigated based on curvature integral by elastic-plastic differences. It was found that entry intermesh section is reduced with increasing thickness and entry intermesh should be from 0.7 to 1.1 mm for LP plate with 42/54 mm in thickness. In order to get satisfactory flatness along longitudinal direction, small entry intermesh should be selected and exit intermesh should be 0 mm. In addition, thickness section for LP plate which can be leveled by 11 roller leveler is from 24 to 60 mm. Finally, there is an intermesh schedule that could level LP plate with initial curvature less than elastic limit curvature.     

中厚板辊式矫直过程弯辊作用分析

 为了进一步提高中厚板产品矫直质量,采用弹塑性差分的曲率积分方法,分析了弯辊对矫直效果的影响,研究了弯辊量与压下量的关系,为建立中厚板辊式矫直过程的弯辊设定模型奠定了基础。计算结果表明,为了使板材矫直后的残余曲率和残余应力最小化,施加弯辊时要考虑入口压下量的影响。单从降低残余曲率的角度考虑,小压下量和大压下量下都可以施加负弯辊,但正弯辊只适用于小压下量。从控制宽度方向残余应力的角度考虑,正弯辊施加于小入口压下量时弯辊作用明显,为了消除正弯辊对厚度方向残余应力的不利作用,采用正弯辊时入口压下量不宜过大。施加弯辊会增加矫直力,因此设定弯辊量时要考虑矫直机能力的限制。研究发现了弯辊对塑性变形率的影响规律：负弯辊出现了使塑性变形率随着入口压下量的增加而减少的阶段,正弯辊可消除塑性变形率为零的阶段。     

Region Division and Stress Analysis for Plate Roller Leveling Process

Recenttechnologicaladvanceinplaterolling haveconsiderablyimprovedtheflatnessofplate.Butflatnesstolerancerequiredbycustomersstill cannotbereachedbyrollingprocessalone,anditis inevitablethatrollerlevelershouldbeinstalled withintheprocessroute.Thetheoryoflev…     

A 2.5-dimensional Analytical Model of Cold Leveling for Plates with Transverse Wave Defects

Waves occurring in cold-rolled plates or sheets can be divided into longitudinal and transverse waves. Classical leveling theories merely solve the problem of longitudinal waves, while no well accepted method can be employed for transverse waves. In order to investigate the essential deformation law of leveling for plates with transverse waves, a 2.5-dimensional(2.5-D) analytical approach was proposed. In this model, the plate was transversely divided into some strips with equal width; the strips are considered to be in the state of plane strain and each group of adjacent strips are assumed to be deformation compatible under stress. After calculation, the bending deformation of each strip and the leveling effect of overall plate were obtained by comprehensive consideration of various strips along with the width. Bending of roller is a main approach to eliminate the transverse waves, which is widely accepted by the industry, but the essential effect of bending of roller on the deformation of plates and the calculation of bending of roller are unknown. According to the 2.5-D analytical model, it can be found that, for plates, it is neutral plane offsetting and middle plane elongation or contraction under inner stress that can effectively improve plate shape. Taking double side waves as an example, the appropriate values of bending of roller were obtained by the 2.5-D analytical model related to different initial unevenness, which was applicable to the current on-line adjusting of bending of roller in rolling industry.