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采用弹塑性力学分析方法,针对拉伸弯曲矫直机用于对具有初始位移缺陷(瓢曲浪形)薄带钢的浪形矫平过程进行机理建模,推导建立以带钢规格材质及初始浪形参数、拉矫工艺参数和拉矫机相关设备参数为自变量的拉矫变形过程浪形矫平功效的解析预测模型。通过定义拉矫过程中带钢宽向进入塑性变形的屈服区域边界位置作为中间变量,以及依次分别建立各项输入条件与屈服位置的关系、屈服位置与工艺条件的关系,建立浪形矫平预测模型的多变量微分方程组。为了验证该机理模型的正确性,分析初始浪形、材料强度、带钢尺寸等初始条件以及弯曲辊半径、拉矫张力等工艺条件对拉矫机对于带钢浪形的矫平改善能力的影响,并应用ABAQUS软件另行建立同样条件下薄带钢拉弯矫直过程的有限元模型,经计算并对比计算结果,两种方法的结果吻合良好。 相似文献
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轻量化薄壁型材三维弯曲结构件是高端装备制造业中一种难成形加工的关键零部件。针对此类制件的高精度、低成本的成形需求,提出一种拉弯-压弯相结合的铝合金型材三维弯曲成形工艺,设计多点联动的拉压复合成形单元体结构,通过水平方向由夹钳带动拉弯,垂直方向由各单元体上液压执行机构压弯,实现"W"形三维弯曲零件的成形,并研制成形装备样机。建立分析成形过程及回弹预测的数值仿真模型,通过试验对模型的有效性进行验证,仿真结果与试验结果回弹变形一致,回弹预测最大误差小于15%。此外,研究拉力对矩形截面型材拉压复合成形件回弹变形的影响规律,预拉伸力较补拉伸力对成形件的回弹减小趋势更为明显,当预拉伸力从零达到临界塑性应力Aσs时,总回弹减少了26.81%,为保证成形件不发生截面畸变和破裂等成形缺陷,确定了预拉伸力为Aσs、补拉伸力为0.3Aσs的最优工艺参数。所提出的多点三维拉压复合弯曲成形工艺解决了W形一类型材传统三维拉弯无法实现的多向曲率半径复杂弯曲成形的技术难题,为实现镜面对称结构件的成对一次成形提供了一种新方法。 相似文献
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汪志强 《物料搬运与分离技术》1998,(4):40-41
在拉伸过程中,毛坯各部分的受力情况与变形情况都不同的,而且随着拉伸过程的进展也在变化。其中拉伸毛坯在凹模与凸模角区的变形,也影响拉伸过程的进行及拉伸件质量。当拉地变形程序过大时,拉伸筒件侧臂内作用的拉应力也大,会使凸模圆周角区附近的毛坯在拉应弯曲变形引起的应力共同作用下,产生过大的变形与厚度变,并且成为危险断面,因此研究保证筒形件工的拉伸工艺是十分重要的。 相似文献
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镀锌薄钢带经常大量应用于冷弯型钢生产中,而在其生产过程中很容易出现板形缺陷。常见的辊式弯曲矫直设备通过单纯弯曲变形对钢带实施矫直,但无法胜任薄带复杂板形的矫正。拉伸弯曲矫直方法将拉伸和弯曲两种矫直工艺相结合,改变了钢带中性层的位置,经过多次拉直、弯曲能够实现钢带全截面延伸,能够同时实现钢带侧弯、波浪变形、坯料楔形等不良板形的矫直。为此我们开发了一种专门用于冷弯生产的小型拉弯矫直设备实现薄钢带的矫直功能。不但详述了设备机械、电气的研制与开发,而且采用有限元分析和现场试验相结合的方式,对特定产品的拉弯矫直工艺进行了研究。 相似文献
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管材无芯弯曲的最小相对弯曲半径 总被引:4,自引:1,他引:3
为了系统研究管材弯曲的变形实质,进行大量管材无芯弯曲试验.结合管材弯曲成形中外侧管壁材料切向受拉的变形现象,分别对可能发生的集中性拉伸失稳和分散性拉伸失稳变形进行分析.给出与管材力学性能相关,且受拉伸失稳约束的最小相对弯曲半径的计算公式,可用于工艺计算,并对管材弯曲成形设计和工艺分析具有一定的参考价值.通过相应的试验分析指出,由于管材制造所形成的残余应变使得材料在管型状态下所表现的力学性能有一定变化,因此管材弯曲作为二次塑性变形,其真实硬化模数及力学性能参数对弯曲过程中材料的失稳变形和最小相对弯曲半径的计算具有重要影响. 相似文献
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The problem of real-time tension control in a metal-strip processing line is addressed. The tension in a metal strip changes
due to not only the speed difference but also thickness changes at the ends of a span. The mathematical dynamic model which
describes relationship between the tension change and the roll-speed change is improved to include the effect of the strip
thickness change on tension variation. Through the computer simulation of this model. the parameter sensitivity analysis and
the static and dynamic characteristic study are carried out. The tension variation in a metal strip turned out to be very
sensitive to the thickness variation as well as to the speed difference at the ends of the metal strip. In the rolling process,
the master speed drive is usually located at the last stand. The speeds of rollers in upstream stands are adjusted with respect
to the speed of the last stand to compensate the speed change for the tension regulation. A new tension control strategy in
a multi-stand rolling process is suggested. The tension transfer phenomena is used in the design of the suggested controller.
The developed mathematical model is used to design a controller for the real-time control system. A set of requirements for
the real-time tension control is suggested. Based on the requirements, a real-time software for the tension control in a multi-stand
system is designed and real-time simulation was carried out by using the Vx Works real-time scheduler and the Force Target
board. The cancellation mechanism of the roll gap control due to the tension interaction is clearly defined by using the mathematical
model derived in this study. It is confirmed that the suggested control strategy needs less control efforts and shows better
performance than those of the existing control method in a rolling process. 相似文献
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模拟板带轧制三维变形的流面条元法 总被引:4,自引:0,他引:4
提出模拟板带轧制过程三维变形的一种新的数值方法——流面条元法。沿着金属的流动轨迹,将变形区划分为若干流面(曲面)条元,为方便分析和计算,又将其映射为平面条元。横向位移和高向位移的纵向分布被分别构造为四次曲线和二次曲线,其横向分布均用三次样条插值函数表示,高向分布均用二次曲线拟合。根据塑性力学流动理论,分析推导了变形区三维变形和应力的数学模型。与曾经提出的流线条元法相比,考虑了应力与变形沿高向的不均匀分布,实现了精确的三维分析和计算。仿真实例表明,该方法和模型符合实际,为板带轧制过程的三维力学仿真提供了一个新的实用工程数值方法。 相似文献
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The mathematical model for tension behaviors of a moving web by Shin (2000) is extended to the tension model considering the
thermal strain due to temperature variation in furnace. The extended model includes the terms that take into account the effect
of the change of the Young’s Modulus, the thermal coefficient, and the thermal strain on the variation of strip tension. Computer
simulation study proved that the extended tension model could be used to analyze tension behaviors even when the strip goes
through temperature variation. By using the extended tension model, a new tension control method is suggested in this paper.
The key factors of suggested tension control method include that the thermal strain of strip could be compensated by using
the velocity adjustment of the helper-rollers. The computer simulation was carried out to confirm the performance of the suggested
tension control method. Simulation results show that the suggested tension control logic not only overcomes the problem of
the traditional tension control logic, but also improves the performance of tension control in a furnace of the CAL (Continuous
Annealing Line). 相似文献
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A new method—the stream surface strip element method (SSSEM)—for simulating the three-dimensional deformations of plate and strip rolling process is proposed. The rolling deformation zone is divided into a number of stream surface (curved surface) strip elements along metal flow traces, and the stream surface strip elements are mapped into the corresponding plane strip elements for analysis and computation. The longitudinal distributions of the lateral displacement and the altitudinal displacement of metal are constructed respectively to be a quartic curve and a quadratic curve, the transverse distributions of them are expressed as the third-power spline function, and the altitudinal distributions of them are fitted to be a quadratic curve. Based on the flow theory of plastic mechanics, the three-dimensional deformations and stresses of the deformation zone are analyzed and formulated. Compared with the streamline strip element method, the SSSEM considers the uneven distributions of stresses and deformations along altitudinal direction, and realizes an accurate three-dimensional analysis and computation. The simulation examples indicate that the method and the model of this paper are in accord with facts, and provide a new reliable engineering-computation method for the three-dimensional mechanics simulation of plate and strip rolling process. 相似文献
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We describe a looper controller design for a hot strip finishing mill in steel plants. The main function of the looper system
is to balance the mass flow of the strip by accumulating material in the middle of the stands. Another function is to control
the strip tension which influences the width of the strip. To ensure strip quality, it is very important to control the tension
of the hot strip finishing mill. However, because there is a mutual interaction between the looper angle and the strip tension,
it is difficult to control the looper system. Previous researches examined only the operation of a single stand. But it is
not sufficient to examine the operation and effect of whole stands because the operation is wholly interdependent. In this
paper, we present a full model of the hot strip finishing mill in order to more effectively control strip tension. We propose
several control methods for the full-stand hot strip finishing mill, denoted as conventional PI, PI with cross gain, and coefficient
diagram method (CDM) PID control. In the real plants, there are some problems by using higher order controllers such as LQ,
LQG and H∞. By comparison, the PID controller is very simple and easy to apply to all real plants. To that end, we present
our findings on PID controls and their potential use in the hot strip finishing mill. 相似文献
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The metal processing system usually consists of various components such as motors, work rolls, backup rolls, idle rolls, sensors,
etc. Even a simple fault in a single component in the system may cause a serious damage on the final product. It is, therefore,
necessary to diagnose the faults of the components to detect and prevent a system failure. Especially, the defects in a work
roll are critical to the quality of strip. In this study, a new 3-D diagnosis method was developed for roll shape defects
in rolling processes. The new method was induced from analyzing the rolling mechanism by using a rolling force model, a tension
model, the Hitchcock’ s equation, and measurement of the strip thickness, etc. Computer simulation shows that the proposed
method is very useful in the diagnosis of the 3-D roll shape. 相似文献
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