基于DEFORM环件轧制塑性成形过程数字仿真

基于通用有限元DEFORM软件建立了环件轧制全过程三维动态仿真模型,对矩形截面环件一个生产周期内轧制过程进行了数值仿真.结果表明,采用合理的网格划分和轧制工艺,能够有效地控制计算时间,模拟的轧制过程真实地反映了环件轧制成形过程,为实际环件轧制过程的毛坯结构设计和轧制工艺优化提供了一个有效研究途径.     

薄壁板件轧制过程的轧制力计算

薄壁板件的连续轧制过程复杂,影响轧制力的参数很多,准确设定轧制力及轧制过程的参数需要花费较多的人力、物力.借助通用显式动力有限元计算程序DYNA对多辊连续轧制过程的轧制力进行计算,得到轧制过程中轧制力的大小,与现场实测的轧制力结果吻合良好.     

无芯棒楔横轧铝合金空心轴微观组织演变规律

铝合金空心轴在楔横轧轧制过程中,其微观组织的演变对轧件的力学性能有重要影响.为得到无芯棒楔横轧铝合金空心轴的微观组织演变规律,通过有限元软件Deform-3D构建有限元模型.对微观组织演变过程进行数值模拟,研究了轧制温度、断面收缩率、展宽角和成形角4个参数对轧件平均晶粒尺寸的影响规律.并通过元胞自动机法揭示了工艺参数与...     

Q235小H型钢轧制过程温度场有限元分析

小H型钢成品的组织性能与轧制过程的温度紧密相关,特别是终轧的温度.结合现场测量结果,应用有限元分析软件对轧制过程的温度场进行模拟,并通过对Q235小H型钢轧制过程各轧制阶段温度的实际测量,与有限元分析结果进行比较,两者误差较小,验证了有限元分析结果的正确性,得到了各阶段H型钢断面温度分布特点以及内外温差值.分析结果对制定加热温度、轧制过程冷却参数、轧制工艺参数和进行轧后控冷等提供了有效参考     

非对称轧制力能参数与带钢张应力分布规律

为深入了解带钢轧制过程中非对称因素对轧制力能参数与带钢张应力分布的影响,应用ABAQUS非线性有限元软件对轧制过程进行二维建模及仿真分析,以轧辊驱动方式非对称、上下工作辊与带钢间接触摩擦润滑条件非对称以及存在异步轧制等3种非对称因素作为研究对象,计算并分析上述非对称因素及其程度对于轧后带钢内部张应力分布、轧制力以及轧制扭矩的影响规律,进而定量分析与比较3种非对称轧制因素对于轧制过程中的力能参数和厚向张应力分布规律的影响程度. 仿真计算表明：3种非对称轧制状态都会导致轧后带钢厚向张应力分布的不对称;3种非对称轧制状态都会明显改变轧制过程力能参数大小;与相应对称轧制状态相比,有些非对称因素可以不同程度地降低轧制力和轧制扭矩. 轧制过程中的非对称因素从不同的角度来分析,是利弊共存的.     

皮尔格冷轧无缝钢管成形过程组织演变过程研究

皮尔格冷轧技术作为冷轧无缝金属管材最主要的技术手段,具有材料利用率高、截面累积变形量大及加工精度高等特点,以LG-60皮尔格冷轧管机轧制304不锈钢为研究对象建立数值仿真模型,分析不同轧制工艺参数对皮尔格冷轧成形的影响规律。结合轧制实验,截取管材不同的变形段利用金相显微镜、扫描电镜以及X射线衍射仪分析研究了皮尔格冷轧过程中钢管组织演变规律,结果表明：本文所使用工艺参数条件均可以满足管材的塑性变形要求,但在轧制过程中极有可能形成裂纹或其他缺陷。因此通过对皮尔格冷轧仿真过程中轧制力、管材等效应力、残余应力以及外径回弹量等关键参数分析,获得基于送进量、回转角和Q值最优工艺参数,同时,发现轧制过程中随着变形量的增大,试样内部产生了大量位错,晶粒发生了碎化,晶粒尺寸减小,轧制过程中有奥氏体γ相转变为α''-马氏体相。     

棒线材无头轧制工艺的分析

无头轧制工艺是轧钢业应用的一种新的轧制技术.对无头轧制和传统轧制的优缺点进行了比较,介绍了无头轧制工艺系统的组成,并对无头轧制的工艺过程、适用范围和潜在的经济性进行了分析.     

82B钢线材精轧过程的再结晶行为

结合某钢厂高碳钢线材生产线轧制82B钢的工艺参数,在Gleeble1500D热模拟实验机上采用不同精轧温度制度模拟了精轧F1-F4阶段该钢的轧制变形,分析了精轧温度对精轧过程中各道次动态再结晶的影响.研究结果表明,精轧F1-F4道次变形温度的控制对82B线材的组织有重要影响,精轧温度特别是精轧出口温度过高易使F4道次轧制发生不完全动态再结晶,不利于组织控制.     

圆坯二辊斜轧单位压下量计算方法

单位压下量是斜轧中的基本变形参数,提高单位压下量计算精度对于轧制力能参数计算和数值模拟建模具有重要意义.基于轧辊开度的概念和变形区分析,对圆坯二辊斜轧轧辊开度计算进行了简化,导出了单位压下量计算公式,并参照实际工艺条件计算了单位压下量,发现单位压下量随轧辊送进角的增大而迅速增大,因而送进角对开度的影响不能忽略.此外,讨论了轧辊送进角对单位压下量产生显著作用的根本原因.导出的公式对圆坯斜轧内撕裂形成数值模拟模型简化、增强模拟可靠性提供必要基础.     

异步轧制过程中的轧制压力研究

应用有限元的方法模拟了异步轧制过程,并对轧制压力进行了分析研究。轧制压力的模拟结果与理论计算结果吻合较好。模拟结果表明,随着速比的增加,轧制压力逐渐减小并趋于稳定。对异步轧机的设计和轧制工艺的制定具有参考意义和应用价值。     

轧件扭转对高速线材轧制稳定性的影响

针对高速线材稳定性问题,综合分析影响线材轧制过程稳定性的因素,运用有限元软件模拟在轧制过程中轧件扭转不同角度的情况,明确了轧件扭转对轧件轧后尺寸和形状的影响,并探讨相应的改进措施.     

30t转炉-小方坯连铸生产ML40Cr冷镦钢盘条的实践

阐述了ML40Cr冷镦钢生产情况,对采用氧气顶吹转炉→LF钢包精炼炉→小方坯连铸→高速线材轧制生产的冷镦钢盘条进行了综合检验分析.结果表明,生产的10 mm盘条金相组织为铁素体＋珠光体,晶粒度9～10级;钢中A、B、D类非金属夹杂物的级别分别为0.5级、1.0～1.5级和1.5～2.0级,单位面积内当量直径5μm的夹杂物个数为20～22个/mm2,夹杂物平均直径为3.656～3.891μm,夹杂物含量相对较少,夹杂物尺寸相对比较细小;轧材的综合力学性能良好,同时具有良好的塑性变形能力,可以满足标准件生产要求.     

Modeling and finite element analysis of rod and wire steel rolling process

Two thermomechanical coupled elastic-plastic finite element （FE） models were developed for predicting the 12-pass continuous rolling process of GCrl 5 rod and wire steel. The distances between stands in the proposed models were set according to the actual values, and the billets were shortened in the models to reduce the calculation time. To keep the continuity of simulation, a technique was developed to transfer temperature data between the meshes of different models in terms of nodal parameters by interpolation functions. The different process variables related to the rolling process, such as temperature, total equivalent plastic strain, equivalent plastic strain rate, and contact friction force, were analyzed. Also, the proposed models were applied to analyze the reason for the occurrence of an excessive spread in width. Meanwhile, it was also utilized to assess the influence of the roll diameter change on the simulated results such as temperature and rolling force. The simulated results of temperature are found to agree well with the measured results.     

Study on Influence of Initial Rolling Temperature for Rolling Process Based on Numerical Simulation

Wire rolling is a typical large deformation process and its principle is very complex,which includes material non- linearity,geometry non-linearity and boundary non-linearity.It is difficult to obtain theory analytical results by trying to roll or physical experiment because they will induce many problems such as high cost,waste time and venture.With the rapid advance- ment of computing technology and numerical method,the finite element method is regarded as the best one,which can account for the large plastic deformation,thermo-mechanical coupling and complex boundary conditions of the rollers and the workpiece inter- actions in the rolling process.Under the different initial rolling temperature,the two-pass hot continuous rolling process of high- speed wire has been simulated accurately for the pre-finishing rolling section.The metal fluxion law and the deformation field have been obtained.Strain,temperature,rolling force and torque also have been simulated and discussed.The results of simulation are useful for practical manufacture and the optimization of process-parameters.     

Static and dynamic finite element analysis of 304 stainless steel rod and wire hot continuous rolling process

Three-dimensional finite element models were developed to analyze 304 stainless steel rod and wire hot continuous rolling process with the help of MSC.Marc software. The entire 30-pass deformation process and the actual parameters of production line were taken into account. Static and dynamic procedures were used to study the continuous rolling process with the aid of the thermo-mechanical coupled FEM of elastic-plasticity. The properties of billets, such as deformation, temperature field and rolling force, were mainly discussed. The simulation results of temperature agree well with the measured values. Comparisons of the analysis results obtained using static implicit method and dynamic implicit method were presented. It is shown that static implicit procedure is more accurate than dynamic implicit procedure and is able to simulate the rolling process with a lower speed, such as a roughing mill. Whereas, dynamic analysis shows a higher efficiency than static analysis and is fit for simulating the rolling process with a higher speed, such as a finishing mill.     

WinCC用户归档在合钢线材轧制表上的应用

在合钢新建的高速线材生产线上,利用WinCC提供的用户归档功能,实现存储轧制表的方案.完成了轧制表中工艺参数的设定及优化操作.     

Remote Monitoring and Diagnosis System for High-speed Wire Rolling Mills

Traditional fault diagnosis systems of rolling mills mostly use single machine monitoring net,which leads the re- al-time data running only in the enterprise locally and can not monitor and manage the high-speed wire rolling mills between units, workshops and factories concentratedly.A new-type structure of remote diagnosis system for high-speed wire rolling mills is pre- sented in this paper.The signal processing,computer network and remote diagnosis etc techniques are used to predictive maintenance manage the rolling mills units in this system.The new structure reinforced the remote feedback function,made up the existing fault diagnosis systems' insufficiency in the extension and the function,promoted resource sharing and avoided the repeat develop- ment.The remote diagnosis example shows that the system can monitor and diagnose the fault information of remote machine timely and effectively.     

滚动轴承动态性能的测试与分析

本文对滚动轴承采用柔性悬挂的方式测试其机械阻抗。根据轴承的支承形式提出了相应的动力学模型,由此动力学模型和测试得到的阻抗曲线识别出滚动轴承的刚度和阻尼值。用本文提出的方法识别得到的滚动轴承动态参数剔除了支承状况的影响,从而使得识别值更符合实际情况。     

新型滚切剪空间剪切机构优化数学模型的建立及应用

以纯滚动剪切为目标,通过对新型滚切剪空间剪切机构的原理分析,建立了增加导向杆为设计变量的剪切机构优化数学模型,以推广应用的某大型钢铁有限公司3000 mm单轴双偏心定尺滚切剪的研发项目为依托,对剪切机构的杆件尺寸进行了优化,对运动轨迹进行了模拟.上下剪刃重叠量,刀弧水平偏移量,开口度的计算结果表明,加入导向杆设计变量的优化数学模型,对求得纯滚动剪切机构的杆件尺寸,降低刀弧水平位移量,均匀剪刃重叠量,保证设定开口度的作用显著.现场生产样机重叠量、刀弧水平综合位移量、开口度的实际值及高质量的钢板剪切断面也证实了上述优化数学模型的正确性.     

轧钢自动化的现状与展望

分别介绍了AGC、AFC、CTC、TMCP等轧制自线材轧制中的应用,简介了人工智能在轧制中的应用,并对其进一步发展做了展望.