大型筒节喷射冷却工艺优化及与传统水槽冷却工艺效果对比

针对大型筒节传统热处理过程中水槽冷却能力差和效率低问题,提出一种大型筒节喷射冷却方法,对大型筒节喷射冷却装置和工艺进行了仿真模拟和实验研究。首先设计了一种位置可调的组合式喷射冷却装置,基于正交实验研究了水流密度、喷射压力、喷射角度和冷却段喷射与间隙时间比对温度均匀性、热应力和冷却时间3个指标的影响,确定了最优参数组合。通过仿真和实验,对比分析了大型筒节喷射冷却与传统水槽深冷工艺效果,结果表明,经喷射冷却后的大型筒节晶粒度和各项力学性能均满足要求,筒节温度均匀性更好、热处理效率更高、热应力在允许范围之内。研究成果可为大型筒节高效短流程生产、绿色制造成形提供理论依据。

Optimization of Spray Cooling Technique for Heavy Cylinder and Comparison with Traditional Cooling Effect with Water Tank

Aiming at the problem of poor cooling performance and low efficiency of water tank in the traditional heat treatment of heavy cylinder, a spray cooling technique was proposed and experimental research were conducted on such technique with a simulative spray cooling device. Firstly, a combined spray cooling device with adjustable position was designed. Then, based on the orthogonal experiment, the effects of water flow density, spray pressure, spray angle, and spray time ratio on temperature uniformity, thermal stress and cooling time were analyzed, and an optimal combination of parameters was determined. Through simulation and experiment, the effects of spray cooling technique and traditional cooling process with water tank were analyzed based on comparison. The results show that the grain size and various mechanical properties of heavy cylinder by using spray cooling technique all meet the requirements. In addition, the cylinder has the better temperature uniformity and the higher efficiency in heat treatment, with thermal stress within the allowable range. This research provides a theoretical basis for the green manufacturing of heavy cylinder with high efficiency and short-process production.