关于钢铁制造流程的研究

在认识钢铁制造流程的动态运行过程中,会遇到不同层次、不同时-空尺度的科学问题.即微观层次(原子/分子尺度)上的基础科学问题,介观层次(场域/装置尺度)上的技术科学问题和宏观层次(制造流程尺度)上的工程科学问题.在钢厂的生产运行过程中,这三个层次上的问题是相互关联并耦合-集成在一起的.在新世纪内应高度注意这类科学问题的研究.钢铁制造流程动态运行的物理本质是:一种多因子"流"按照特定的"程序",在一个复杂网络(流程系统的框架,例如钢厂总平面布置图等)中的流动运行现象.这是属于一类开放的不可逆过程,即物质、能量的转换与耗散过程."流"的行为(特别是碳素流的行为)研究,引起了对钢铁制造流程功能拓展的思考.即钢铁制造流程的功能,不仅是冶金-材料制造功能,还须包括能源转换功能和某些废弃物的消纳-处理和再资源化功能.对钢铁制造流程的结构-功能-效率进行了深入的研究,可系统地、准确地从工程科学层面上对其进行概括、抽象和动态描述,将对工程设计的思维逻辑、企业技术改造的指导思想,钢厂转型和新建钢厂的理念都会产生重要的影响.     

铝生产结构调整与节能对策研究

针对我国铝工业面临的整体性问题,在冶金流程工程学的理论体系框架下,分析研究铝生产设备与流程的节能方向和技术路线,促进铝工业生产流程结构调整。基于现有铝工业的生产流程结构特征及能源利用情况,对比分析铝、钢铁生产流程的冶金本质,划分铝生产流程工序区段,综合分析铝工业能源结构及能量耗散规律。参照钢铁节能技术的实践,指出铝工业在流程优化与改进、能源结构优化、废弃物资源化利用及余能回收综合利用等方面具有系统节能潜力,提出铝后工序高效、有序运行的生产流程结构模式。     

关于钢铁制造流程优化与产品优化问题的讨论

强调在新世纪里中国钢铁企业要注意研究钢铁制造流程的功能 ,指出制造 (生产 )流程对钢厂的生存和发展有着广泛的关联度和综合影响力 ,制造流程的结构优化是钢厂增强市场竞争力和拓展社会经济功能的有效手段。简要地叙述了钢铁制造流程的构成要素是“流”、“流程网络”和“程序”。“流”按一定的“程序”在“流程网络”中动态有序地、准连续地、紧凑地运行 ,可以实现多目标优化。讨论了中国钢铁企业生产流程优化的现状和发展方向 ,还就中国钢铁产品优化过程中有关炼钢、轧钢方面的问题进行了总体性探讨。在新世纪前 2 0年 ,要集中有关资源加速发展薄板及其深加工产品 ,以实现中国钢铁产品的结构调整 ,同时也促进了钢厂结构的优化     

关于钢铁制造流程优化与产品优化问题的讨论

强调在新世纪里中国钢铁企业要注意研究钢铁制造流程的功能,指出制造(生产)流程对钢厂的生存和发展有着广泛的关联度和综合影响力,制造流程的结构优化是钢厂增强市场竞争力和拓展社会经济功能的有效手段。简要地叙述了钢铁制造流程的构成要素是"流"、"流程网络"和"程序"。"流"按一定的"程序"在"流程网络"中动态有序地、准连续地、紧凑地运行,可以实现多目标优化。讨论了中国钢铁企业生产流程优化的现状和发展方向,还就中国钢铁产品优化过程中有关炼钢、轧钢方面的问题进行了总体性探讨。在新世纪前20年,要集中有关资源加速发展薄板及其深加工产品,以实现中国钢铁产品的结构调整,促进钢厂结构的优化。     

钢铁生产中全连续流程的进步

阐述钢铁生产中全连续流程的进充程钢厂的进展，包括短流程钢厂的薄、中薄板的连铸连轧线，大型钢铁联合企业发展高速铸机、改造热连轧系统，发展酸洗－－冷连轧－－退火连续生产线，建立全连续生产流程等内容，并提出今后全连续流程发展的见解。     

先进钢铁生产流程进展及先进钢铁材料生产制造技术

简要回顾了20世纪钢铁工业生产总量、钢材质量、劳动生产率、原料及能源消耗的状况,介绍了氧气转炉炼钢、连续铸钢、炉外精炼及控冷控轧技术的特点及优势,指出了钢铁工业发展所存在的环境污染严重、能源及资源循环使用率低、钢材服役周期短等问题,描述了现代钢铁生产流程连续、高效、柔性、可控的发展特征.展望了21世纪先进钢铁生产流程中氢冶金、第2代薄板坯连铸连轧及铸-轧-材一体化等流程技术的实现.在此基础上,简要介绍了先进钢铁材料的特征及生产制造技术进展.     

钢铁生产流程铁资源效率与工序铁资源效率关系的分析

以钢铁生产流程铁流图为基础，推导了实际钢铁生产流程铁资源效率与工序铁资源效率的关系式．以某钢厂年均生产数据为例，分析了流程铁资源效率与工序铁资源效率的关系，并讨论了工序铁资源效率对流程铁资源效率的影响．     

冶金工序功能的演进和钢厂结构的优化

本文对钢厂生产流程中各单元工序的功能演进以及整个冶金工程的组成内涵所发生的巨大变化进行了评估.第二次世界大战结束后,以间歇/准连续流型和流程长为特点的钢厂工艺流程进步的基本动向是;单元工序功能的分析、分解和优化;各工序优化了的功能在工程中的组合优化;工序之间的衍接、匹配互程——广义“活套”工程这实际上是一种长工艺流程中的物流多维管制系统.文中概括了这类物流多维管制系统的几个主要领域.本文对正在发展着的新一代钢厂工艺流程也作了评论在上述评估、归纳的基础上,研究了一系列工艺技术的替代/淘汰关系及其对钢厂结构的影响,进而从全球(包括发达国家和发展中国家)视角上讨论了各类有竞争力的钢厂结构的优化方向     

钢铁生产流程的物流对能耗的影响

提出了钢铁生产流程基准物流图的概念,分析了偏离基准物流图的各股物流对吨材能耗和吨钢能耗的影响.以某钢厂生产数据为例,分析了生产流程的物流对能耗的影响.     

钢铁流程结构分析及能耗评价

钢铁制造流程是一个由多个工序组成的复杂的物理化学过程,物质流和能量流按照一定的路径和规律在工序系统间运行。文章从钢铁制造流程物质流和能量流分析出发,把传统钢铁长流程划分为四个层次,构建了以铁素物质流为主线,能源转换环节相对独立的流程能耗分析和评价体系。     

谈财务管理在无缝钢管生产经营决策中的运用

随着市场经济的发展 ,财务管理在企业中的作用显得日益重要 ,无缝钢管作为一种特殊的钢材产品 ,其生产过程与其他钢材相比具有其特殊性。通过财务管理在无缝钢管成本计算、生产安排、投资决策等方面的应用 ,阐述了财务管理在无缝钢管生产经营决策中的作用。     

Application of methods for ecological optimization of crank shaft forging process

The manufacturing process of forged parts is usually conducted by different subsequent process steps. According to various technological as well as economical and ecological requirements, different and often opposing objectives have to be fulfilled. A representative example for this conflicting situation is the requirement of high product qualities on the one hand and low processing costs on the other hand. A third important factor influencing the process in addition to quality and cost-efficiency is the ecological aspect that is focused more and more in recent years. Material shortage, high energy costs and increasing intensification of statutory regulations lead to the necessity of ecologically optimized processes. Nevertheless, an economic-based evaluation of forging processes is not easy to carry out due to a versatile process chain from raw material to final product. Within the framework of the joint research project “Holistic process chain optimization for forging production of automotive parts in terms of manufacturing efficiency and saving operation energy” an entire evaluation and optimization with special regard to ecologic aspects will be conducted on the example of a crank shaft forging process (Denkena et al. in ZWF 4:224–228, 2013; Int J Precis Eng Manuf 14(7), 2013).     

Reprocessing of AW2007, AW6082 and AW7075 aluminium chips by using sintering and forging operations

Since its discovery in the late Nineteenth century aluminium becomes an important construction material due to its good mechanical properties such as sufficient strength at low density. Additional advantages are high corrosion resistance as well as low manufacturing forces. Apart from this, aluminium is still very expensive to produce. The energy consumption of the production process is at least twice as much as for steel. Most of the energy consumption takes place at the electrolyse process while aluminium oxide (Al₂O₃)—recovered from natural bauxite—is divided into unalloyed aluminium named “primary aluminium” and CO₂. Contrary to the expensive production of primary aluminium the energy consumption of the recycling process of used aluminium also known as “secondary aluminium” is considerably lower. Given this huge effort in producing primary aluminium, the recycling of aluminium is an important economic and ecological approach. The common recycling method for aluminium is to melt it in a furnace. Except from small-sized scrap like chips, this is an overall efficient recycling method for most aluminium scraps. It can be observed that especially chips suffer high material losses mostly due to contaminants from the production process (cooling lubricant, oil etc.), fire losses (oxidation), slag and unadapted furnace settings. For this reason, several researches examine alternative recycling processes to avoid a melting process and minimize material losses. In this investigation a new non-melting aluminium recycling approach will be validated. For this purpose various chip pressings (turning, milling, sawing) are forged with an upsetting press. It will be shown that it is possible to generate a solid consolidation without pores in areas of high material movement. Furthermore, the effect of a previous sintering operation will be examined.     

河钢集团唐钢大型型钢产线产品开发及技术创新

针对大型型钢产线工艺布置及设备特点,河钢集团唐钢公司开发了30#特大角钢及热轧U型钢板桩、电极扁钢等系列产品,主要介绍了系列新产品的化学成分及孔型设计;围绕大型型钢产品的特点,介绍了该产线的技术创新,如首台无级可变不等节距双支撑矫直机功能的优化,全液压式步进冷床功能的完善,型钢生产全流程综合管理系统的研发与应用,以及多...     

采用新材料、新结构、新工艺技术,攻克零件变形关

某变速箱产品主减速齿轮因最终热处理后变形大而只能采用加工效率低、制造成本高的磨齿工艺.通过综合分析,认为其变形大的原因在于:一是零件形状结构较特殊,二是钢材的综合质量性能欠稳定,三是坯件预先热处理质量及渗碳/碳氮共渗、淬火相关参数的搭配欠佳.为此,提出了采用新材料、新结构、新工艺对此进行攻关,以期将磨齿工艺改为剃齿工艺.结果表明:零件的结构改进、材料选择、工艺流程等基本合理,可以生产出变形满足技术、装配和使用寿命要求的产品.剃齿工艺替代磨齿工艺投入生产应用后,大幅度提高了生产效率、降低了制造成本,且有利于提高零件使用寿命.     

An inverse approach to the numerical design of the process sequence of tailored heat treated blanks

While in industries lightweight construction gain an increasingly significant role and as weight reduction is often done with aluminum sheets, advanced production technologies have to be developed to be competitive for this evolution. Since steel sheet metal parts cannot be substituted directly with aluminum due to its minor formability, the usage of so called tailored heat treated blanks (THTB) is presented in this work. THTB are locally heat treated aluminum blanks from the 6,000-series alloy which exhibit a specific strength pattern optimized to the forming operation leading to a significantly improved formability for the manufacturing of complex aluminum car body parts. The enhancement of the formability is reached by a local heat treatment before the forming process. Due to the strong interdependency of heat treatment and forming operation, a numerical investigation of the process sequence is a prerequisite for a cost-effective usage of the THTB. An inverse approach on basis of a finite element simulation enables the determination of process parameters for an optimized THTB, thus having an effective and efficient engineering method for this technology. The investigations presented in this paper were carried out within the project CRC 396 B4 “Robust, shortened process sequences for lightweight sheet parts” sponsored by the German Research Foundation (DFG).     

冷轧高强度钢板生产工艺探讨

轻量化是汽车“减重节能”的需要,采用高强度钢板已被证明是最佳的材料技术解决方案。为适应汽车行业对材料高强化的要求,解决钢铁企业对冷轧高强度钢板生产工艺的困扰,通过对国内外冷轧高强度钢板生产技术和使用技术的实践分析,探讨了冷轧高强度钢板的生产工艺。     

Design and management of manufacturing systems for production quality

Manufacturing companies are continuously facing the challenge of operating their manufacturing processes and systems in order to deliver the required production rates of high quality products, while minimizing the use of resources. Production quality is proposed in this paper as a new paradigm aiming at going beyond traditional six-sigma approaches. This new paradigm is extremely relevant in technology intensive and emerging strategic manufacturing sectors, such as aeronautics, automotive, energy, medical technology, micro-manufacturing, electronics and mechatronics. Traditional six-sigma techniques show strong limitations in highly changeable production contexts, characterized by small batch productions, customized, or even one-of-a-kind products, and in-line product inspections. Innovative and integrated quality, production logistics and maintenance design, management and control methods as well as advanced technological enablers have a key role to achieve the overall production quality goal. This paper revises problems, methods and tools to support this paradigm and highlights the main challenges and opportunities for manufacturing industries in this context.