PC轧机轧制过程耦合数值模拟研究

开发了一种分析三维板带轧制过程轧件与轧辊的耦合变形的计算机模拟系统。它耦合了三维刚塑性有限元法,弹性有限元法和计算辊系变形的影响函数方法。采用该系统成功地对PC轧机(Paircrossedrollingmill)轧制过程进行了分析,得到了轧制压力横向分布,前后张力横向分布,金属横向流动,以及轧后板带的横向板厚分布,包括板凸度和边部减薄大量信息等。     

入口侧辊板非对称接触轧制时的变形效应

针对中厚板轧制时前端部板形翘曲这一生产中常见的技术问题,在轧机上通过静态压缩、轧制试验,观察、分析了入口侧辊板非对称接触对轧制过程的影响.探讨了轧制时变形区几何形状系数l/对轧件前端部翘曲的影响规律.指出入口侧辊板非对称接触轧制时,金属沿高向变形与流动、应力分布呈非对称状态,使金属沿高向上的纵向流动不均匀,这是导致轧件出辊缝后前端部翘曲的主要因素之一.     

喷射沉积多孔材料的轧制变形理论

根据"表观总应变能达到一个临界值时材料开始屈服"这一概念,研究和建立了多孔材料轧制塑性变形屈服准则,根据"多孔材料变形时质量不变"原理建立了轧制变形过程中高向变形与相对密度、高向变形与纵向变形、泊松比与相对密度的关系.理论预测与用喷射沉积制备的FVS0812耐热铝合金多孔材料的轧制结果符合得较好;建立了多孔材料轧制变形相对密度与高向应力的关系,提高多孔材料所处的压应力状态可以加速材料的致密化速度,改善多孔材料的轧制成形性能.     

六辊轧机扭振动态建模及与板带钢质量关系研究

考虑轧机扭振与辊系沿轴向动态特性和板带材质量的关系,基于连续体动力学建立了六辊轧机扭振动力学模型,包括轧机辊系等效模型和辊身与辊径过渡部分等效模型。根据轧制速度与轧辊角速度的关系,建立了板带钢前后张力、轧制力等参数与辊系扭振的关系模型。基于所建模型对某六辊轧机施加位移激励模拟扭振情况,仿真分析了轧机辊系和板带钢在扭振激励下的三维动态响应。仿真结果表明,轧辊角位移和角速度沿辊身长度方向波动较小;轧辊扭振使轧制压力、前张应力和后张应力横向分布发生不同程度的波动,扭振对前张应力分布影响较大,即对板带钢板形产生影响,且传动侧的波动幅值大于操作侧。     

搅拌铸造SiCp/2024复合材料热挤压-轧制变形组织及性能

利用搅拌铸造-热挤压-轧制工艺制备SiCp/2024复合材料薄板。通过金相观察(OM)、扫描电镜(SEM)及力学测试等手段研究了该复合材料在铸态、热挤压态及轧制态下的显微组织及力学性能,分析了材料在塑性变形过程中显微组织及力学性能的演变。结果表明,该复合材料铸坯主要由80～100μm的等轴晶组成,粗大的晶界第二相呈非连续状分布,SiC颗粒较均匀地分布于合金基体中;热挤压变形后,晶粒沿挤压方向被拉长,SiC颗粒及破碎的第二相呈流线分布特征;轧制变形后,基体合金组织进一步细化,晶粒尺寸为30～40μm,SiC颗粒破碎明显,颗粒分布趋于均匀,轧制变形对挤压过程中形成的SiC颗粒层带状不均匀组织有显著的改善作用。数学概率统计指出,塑性变形有利于提高颗粒分布的均匀性。力学测试表明,塑性变形后,复合材料的抗拉强度、屈服强度和延伸率显著提高。SiCp/2024铝基复合材料主要的断裂方式为:合金基体的延性断裂、SiC颗粒断裂及SiC/Al界面脱粘。     

6061-T6铝合金中厚板-节点套多层多道焊数值模拟

为研究铝合金中厚板-节点套接头在多层多道焊后的残余应力和变形分布,本文基于ABAQUS软件建立了该接头三维有限元模型,采用双椭球热源、生死单元法以及顺序耦合法,对6061-T6铝合金中厚板-节点套多层多道焊进行数值模拟,并分析了接头的温度场,以及在夹具约束下的焊接残余应力及变形的分布情况。研究结果表明:数值模拟与实际接头的熔池形状吻合度较高;摆动焊接过程中温度曲线呈多峰结构;焊件的升温速率明显大于冷却速率,且冷却速率随时间逐渐减小;焊接残余应力主要集中在焊缝及夹具区域,且小于6061-T6铝合金在室温下的屈服强度;接头的最大横向残余应力为129.9 MPa,中厚板上的横向残余应力大于节点套上的横向残余应力;接头的最大纵向残余应力为132.9 MPa,沿焊接方向,焊缝处的纵向残余应力呈山峰状分布;该接头在Y轴方向上的变形最大,为1.494 mm,该接头的最终变形结果为上凸变形。     

钛钢复合板双金属的流变行为及轧制制备

基于采用单轴压缩实验得到的钛钢双金属流动变形规律,对钛钢复合板进行了不同工艺的轧制及热处理,并系统分析了不同工艺下钛钢复合板的微观组织、界面特征以及力学性能。结果表明,随着钛钢厚度比的增大、变形温度的升高,双金属流动性差异增大;根据应力-应变曲线,采用Levenberg-Marquardt法建立了变形抗力预测模型,预测应力值与实测应力值拟合优度为0. 961;钛钢复合板在800～900℃进行大压下量轧制得到的板材力学性能最优。在750℃下进行热处理时,界面处TiC层较厚且厚度不均匀;在850℃下进行热处理时,界面处TiC层平直且厚度均匀。在950℃下进行热处理后,界面化合物以TiFe为主,TiC分布于Ti Fe两侧且呈分层分布。同时,铁素体基体出现TiC沿晶界、晶内析出现象,增大冷却速度可对析出物的尺寸进行控制。     

轧制变形量对铸轧铅合金板带性能的影响

从阳极极化稳定电位、腐蚀速率、阳极极化前后表面形态与物相组成、导电性能、力学性能等方面研究了轧制变形量对铸轧铅合金板带性能的影响。结果表明:轧制前后铅合金板带的阳极极化电位变化不大,但能明显提高铅合金的抗腐蚀性能和力学性能。同时随着轧制变形量的增大,铅合金板带的导电性能有所下降。特别是经过两道次变形量为30%的轧制后,抗腐蚀性能是轧制前的1.48倍;同时铅合金板带的抗拉强度σb和屈服强度σp0.2分别提高了28.5%和79.4%,硬度HBS提高了2.8。     

三维轧制问题接触应力的数值分析

本文采用修正刚塑性有限元法计算了三维轧制问题的接触应力,并分析和讨论了不同长高比时接触应力沿轧件纵向和横向的分布情况。计算结果与实验结果相吻合。     

强剪切对单层晶极薄带轧制变形行为的影响

为确定最优的极薄带轧制工艺,本研究深入分析了强剪切对轧制单层晶极薄带微观变形行为和晶体转动演化的影响。采用基于位错滑移机制的晶体塑性有限元模型进行模拟,最大异速比达到1.5。建立了晶粒取向随机分布的单层晶极薄带轧制模型,以探究少晶组织的晶界作用特性。结果表明：强剪切导致单层晶极薄带轧制微观变形和晶体转动表现出显著的局部化。强剪切促进了晶粒的剪切变形,使得晶界的协调变形能力增强。在轧制区施加强剪切变形,可使已启动滑移得到扩展,主滑移带缩窄分散形成新的次滑移带,滑移更加集中和各向异性。变形后晶粒取向主要绕箔材宽度方向发生转动和分散,强剪切使转动角度增大和分散点更加集中稳定。模拟表明强剪切严重影响单层晶极薄带轧制变形的各向异性,进而导致择优取向、滑移局部化以及非均匀应力-应变分布。     

Streamline strip element method for analysis of the three‐dimensional stresses and deformations of strip rolling

This paper puts forward a new method—the streamline strip element method (SSEM) for simulating the three‐dimensional stresses and deformations of strip rolling process. The rolling deformation zone is divided into a number of streamline strip elements along metal flow traces, and the streamline strip elements are mapped onto the corresponding rectangle strip elements for computation. The longitudinal distribution model of the metal lateral displacement is constructed to be a quartic plus cubic curve. The three‐dimensional deformations and stresses of the deformation zone are formulated. For the cold strip rolling on a 300 mm wide four‐high mill, the computed results of the transverse distributions of the rolling pressure and the front and back tension stresses are close to the experimental ones. For the cold strip rolling on a 1850 mm wide six‐high CVC mill, the computed results of the transverse distributions of the front tension stress are also close to the experimental ones. This proves that the streamline strip element is a reliable engineering–computation method, and of great importance to developing the mathematical model of the shape control of strip rolling. Copyright © 2001 John Wiley & Sons, Ltd.     

Transverse Distributions of Front and Back Tension Stresses in Cold Strip Rolling

In this paper,such a new lateral displacement function is proposed that the lateral flow velocity is con-tinuous at the entry and the exit of deformation zone.A new kind of finite strip method—the third powerB-spline finite strip method—is put forward to simulate strip rolling process.Front and back tension stressesare formulated.The computed results of the transverse distributions of the front and back tension stresses areclose to the experimental results.The paper lays a foundation for further analysing the three-dimensionalstresses and deformations of strip rolling.     

大宽厚比冷轧带材三维应力分布的样条有限条分析

本文在轧件宽厚比为６２５的条件下，用三次样条函数有限条法研究了冷轧带材三维应力的分布问题。获得了轧后边浪和中浪两种不同板形条件下的应力分布规律。对板形理论和板形控制技术的发展有指导意义。     

研究带材轧制过程金属横向流动的一个新方法

根据实测两向单位摩擦力,提出了确定带材轧制过程金属横向位移的新方法。用该方法对冷轧铝带不同宽厚比、轧后边浪和中浪的情况进行了研究。研究结果与已有的试验和理论研究结果相一致。     

Complete Mill Simulation of the Rolling Process of 1660 mm Hot Strip Continuous Mills

The three-dimensional plastic deformations of strip are analyzed using the stream surface strip element method, the elastic deformations of rolls are analyzed using the influence coefficient method, the analyzing and computing model of shape and crown of 4-high mill was established by combining them, and the rolling process of 1660 mm hot strip continuous mills was simulated. The simulated results tally well with the experimental results. The modei and the method for simulation of shape analysis and control of hot strip mills were provided.     

STRIP DISTRIBUTED TRANSFER FUNCTION METHOD FOR ANALYSIS OF PLATES

A semi-analytical method, called the strip distributed transfer function method, is developed for analysis of plate structures that are composed of rectangular plates. In the method, a rectangular plate (substructure) is divided into a number of strips; the response of each strip is interpolated in the unknown nodal line displacements, which are functions of the strip longitudinal co-ordinate and time. The nodal line displacements are determined in an exact and closed form by the distributed transfer functions that are defined along the strips. Synthesis of the substructures using the strip distributed transfer functions yields accurate prediction of the static and dynamic response, natural frequencies and buckling loads of the structure. The proposed method is compared with some existing techniques in numerical examples.     

Finite strip buckling and free vibration analysis of stepped rectangular composite laminated plates

A general spline finite strip method is presented which allows the spline knots to be located arbitrarily along the plate strip and also facilitates the use of analytical integration in evaluating strip properties. The development takes place in the contexts of first‐order shear deformation plate theory and of classical plate theory, and encompasses composite laminated material. The prediction of natural frequencies and buckling stresses of stepped rectangular plates is considered using the new approach in which refinement of knot spacings is used local to a step change. The superstrip concept is used as part of an efficient solution procedure. A number of applications demonstrate the validity and practicability of the developed method. Copyright © John Wiley & Sons, Ltd.     

C0 REISSNER–MINDLIN MULTILAYERED PLATE ELEMENTS INCLUDING ZIG-ZAG AND INTERLAMINAR STRESS CONTINUITY

Concerning composites plate theories and FEM (Finite Element Method) applications this paper presents some multilayered plate elements which meet computational requirements and include both the zig-zag distribution along the thickness co-ordinate of the in-plane displacements and the interlaminar continuity (equilibrium) for the transverse shear stresses. This is viewed as the extension to multilayered structures of well-known C⁰ Reissner–Mindlin finite plate elements. Two different fields along the plate thickness co-ordinate are assumed for the transverse shear stresses and for the displacements, respectively. In order to eliminate stress unknowns, reference is made to a Reissner mixed variational theorem. Sample tests have shown that the proposed elements, named RMZC, numerically work as the standard Reissner–Mindlin ones. Furthermore, comparisons with other results related to available higher-order shear deformation theories and to three-dimensional solutions have demonstrated the good performance of the RMZC elements.