异型坯连铸过程中结晶器铜板及铸坯热力行为数值模拟研究
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摘要
H型钢是一种经济断面型材，其力学性能和使用性能十分优越，一经问世就广泛应用于国民经济建设的各个领域之中。异型坯作为生产H型钢的最佳坯料，具有能耗低、工序少、成材率高、成本低等优点。目前，异型坯连铸生产过程中铸坯存在着较多的表面和内部质量缺陷，难以满足现代连铸技术的发展要求。因此，深入开展异型坯连铸过程中结晶器铜板和铸坯热力行为的研究，探讨影响结晶器铜板使用寿命的因素和铸坯质量缺陷产生的原因，具有极其重要的理论意义和实用价值。
异型坯连铸过程中结晶器铜板的热力行为是影响其使用寿命和铸坯质量的关键因素之一。本论文首先建立模拟异型坯连铸结晶器铜板热弹塑性蠕变行为的有限元模型，利用ABAQUS软件用户子程序定义非线性材料本构关系和传热及力的边界条件，实现模拟结晶器铜板升温、浇注和冷却循环过程的数值方法。利用得到的数值方法，模拟研究大孔结晶器铜板和小孔结晶器铜板在升温、浇注和冷却循环过程中的温度、变形和应力分布，并利用循环非弹性应变结果估算结晶器铜板的疲劳寿命。进而模拟研究不同修磨厚度和冷却水流量对该两种结晶器铜板热力行为的影响。结果表明，不同水缝设计的结晶器铜板温度和变形分布差异明显；小孔结晶器铜板的温度峰值较低、热面温度和变形分布较均匀，因而具有较长的使用寿命和更优的铸坯质量；铜板修磨后厚度减小，温度峰值降低，热面变形减小，热面温度和变形分布更为均匀；增大水缝中冷却水流量对铜板传热和变形的影响规律与减小铜板厚度一致。基于前述研究结果，提出一种改进的水缝设计方案。数值模拟分析表明，该改进方案优于现有的大孔和小孔水缝设计。
研究铸坯在结晶器内凝固及变形对浇注工艺的改进和产品质量的提高极为重要。为模拟结晶器内铸坯的凝固与变形，提出了一种在铸坯凝固界面施加钢水静压力的方法。利用ABAQUS用户单元子程序UEL定义一种与铸坯单元共结点的静水压力单元，实现铸坯凝固界面上钢水静压力的施加，同时利用ABAQUS软件用户子程序GAPCON模拟铜板热面和铸坯表面间的气隙传热，实现模拟异型坯结晶器内铸坯凝固及变形的数值方法。建立了二维瞬态热弹塑性有限元模型，模型中考虑了钢种溶质元素偏析行为对材料高温物理属性的影响。对大孔结晶器和小孔结晶器内铸坯凝固及变形进行了数值模拟，得到铸坯和结晶器壁间的气隙、铸坯和铜板的温度以及铸坯的变形和应力分布。结果表明，气隙是影响铸坯凝固传热的关键，需严格加以控制。该两种结晶器内铸坯在翼缘端部位置气隙较大，坯壳厚度较薄，需适当增加结晶器翼缘端部处的锥度以减小气隙，使得铸坯均匀散热，减少铸坯裂纹的发生。
铸坯在结晶器内和二冷区的凝固传热过程对研究铸坯表面和内部裂纹形成原因极为关键。为此，本论文提出了一种通过移动传热边界条件实现结晶器和二冷区内铸坯凝固传热过程的三维数值模拟方法。移动传热边界条件利用ABAQUS用户子程序DFLUX和FILM实现。利用这一数值方法，模拟研究了冷却工艺条件改进前后铸坯的凝固过程。结果表明，改进前冷却工艺条件下铸坯表面横向温度分布不均，不能满足二冷区表面温度控制准则；改进后的冷却工艺方案既能使铸坯表面温度控制在合理的范围内，又提高了铸坯表面横向温度分布的均匀性，应用于实际浇注后，铸坯质量得到明显改善。
As an economic section material, H-beam with its obvious mechanical andfunctional properties has been used in many fields of national economy developmentsince its first appearence. Beam blank is the idealist strand for H-beam production.Rolling H-beam by beam blank has some significant advantages, such as low energyconsumption, less process, high finished product rate and low cost. During beam blankcontinuous casting, there are many surface and inner defects in the strand which can notbe satisfied with the developing requirment of continuous casting technology innowadays. Therefore, studying on the thermo-mechanical behavior of mold and strandand researching on the key factors which shorten the mold service life and cause thedefects during beam blank continuous casting have great significance to the economyand science.
Thermo-mechanical behavior of beam blank mold during continuous casting is oneof the key factors for the mold service life and product quality. In this paperthermo-elastic-plastic creep finite element models of beam blank molds were firstlyestablished, and the numerical method for the simulation of the cyclic process ofheating, casting and cooling were carried out. The user defined subroutines in ABAQUSwere developed to define the nonlinear material constitutive relationship and boundaryconditions. The distributions of temperature, distortion, and stress across the hot facesas well as the fatigue life of the two molds, the large hole mold and the small hole mold,were numerically simulated, based on which the influences of mold grinding thicknessand cooling water flow were discussed. The results show, there is a notable differencebetween molds with different water slot designs. The distributions of temperature anddistortion of the small hole mold are more uniform than those of the large hole mold,and the peak temperature of the former mold is smaller than that of the later mold.Increasing mold grinding thickness or cooling water flow is benifical for mold toachieve lower peak temperature and uniform temperature and distortion. An improvedwater slot design was proposed and it is superior to those molds by numerical analysis.
It is also important for studying the solidification and distortion of strand duringmold to improve casting process and product quality. For simulating the solidificationand distortion of strand during mold, a method for the application of ferrostatic pressureon the front of solidification was proposed. By means of ABAQUS user defined subrountine UEL, a kind of ferrostatic pressure element shares the same nodes with thestrand element which was used to simulate the ferrostatic pressure on the front ofsolidification, was obtained. By means of GAPCON, the heat transfer between thestrand and mold was carried out. A transient thermo-elastic-plasitc finite element modelwas developed, and the influence of solutes microsegregation on material propertieswas taken into account. The distributions of gap between the strand and mold, strandand mold temperature, strand distortion and stress of two molds were obtained. Theresults show, gap is a key factor for the strand solidification, which must be controlled.The taper should be increased to reduce the gap in the flange tip, owing to the large gapand thin shell thickness.
It is known that the surface temperature of the strand must be carefully controlledin the process because it is a key factor in inducing defects, such as internal and surfacecracks. Therefore, a three dimensional simulation method of moving heat tranferconditions was presented to calculate the solidification process of strand. The userdefined subroutines DFLUX and FLIM in ABAQUS were developed to apply thecomplex heat transfer boundary conditions. Based on the method, the temperaturedistribution of the strand was numerically investigated under original and improvedcooling schemes. The results show, the original cooling scheme could not meet themetallurgical principles of beam blank continuous casting. By the numerical simulationthat the uniformity of transverse surface temperature on cross-sections of the beamblank was improved, and better product quality was obtained after the improved coolingscheme was employed in the steel plant.
异型坯连铸过程中结晶器铜板的热力行为是影响其使用寿命和铸坯质量的关键因素之一。本论文首先建立模拟异型坯连铸结晶器铜板热弹塑性蠕变行为的有限元模型，利用ABAQUS软件用户子程序定义非线性材料本构关系和传热及力的边界条件，实现模拟结晶器铜板升温、浇注和冷却循环过程的数值方法。利用得到的数值方法，模拟研究大孔结晶器铜板和小孔结晶器铜板在升温、浇注和冷却循环过程中的温度、变形和应力分布，并利用循环非弹性应变结果估算结晶器铜板的疲劳寿命。进而模拟研究不同修磨厚度和冷却水流量对该两种结晶器铜板热力行为的影响。结果表明，不同水缝设计的结晶器铜板温度和变形分布差异明显；小孔结晶器铜板的温度峰值较低、热面温度和变形分布较均匀，因而具有较长的使用寿命和更优的铸坯质量；铜板修磨后厚度减小，温度峰值降低，热面变形减小，热面温度和变形分布更为均匀；增大水缝中冷却水流量对铜板传热和变形的影响规律与减小铜板厚度一致。基于前述研究结果，提出一种改进的水缝设计方案。数值模拟分析表明，该改进方案优于现有的大孔和小孔水缝设计。
研究铸坯在结晶器内凝固及变形对浇注工艺的改进和产品质量的提高极为重要。为模拟结晶器内铸坯的凝固与变形，提出了一种在铸坯凝固界面施加钢水静压力的方法。利用ABAQUS用户单元子程序UEL定义一种与铸坯单元共结点的静水压力单元，实现铸坯凝固界面上钢水静压力的施加，同时利用ABAQUS软件用户子程序GAPCON模拟铜板热面和铸坯表面间的气隙传热，实现模拟异型坯结晶器内铸坯凝固及变形的数值方法。建立了二维瞬态热弹塑性有限元模型，模型中考虑了钢种溶质元素偏析行为对材料高温物理属性的影响。对大孔结晶器和小孔结晶器内铸坯凝固及变形进行了数值模拟，得到铸坯和结晶器壁间的气隙、铸坯和铜板的温度以及铸坯的变形和应力分布。结果表明，气隙是影响铸坯凝固传热的关键，需严格加以控制。该两种结晶器内铸坯在翼缘端部位置气隙较大，坯壳厚度较薄，需适当增加结晶器翼缘端部处的锥度以减小气隙，使得铸坯均匀散热，减少铸坯裂纹的发生。
铸坯在结晶器内和二冷区的凝固传热过程对研究铸坯表面和内部裂纹形成原因极为关键。为此，本论文提出了一种通过移动传热边界条件实现结晶器和二冷区内铸坯凝固传热过程的三维数值模拟方法。移动传热边界条件利用ABAQUS用户子程序DFLUX和FILM实现。利用这一数值方法，模拟研究了冷却工艺条件改进前后铸坯的凝固过程。结果表明，改进前冷却工艺条件下铸坯表面横向温度分布不均，不能满足二冷区表面温度控制准则；改进后的冷却工艺方案既能使铸坯表面温度控制在合理的范围内，又提高了铸坯表面横向温度分布的均匀性，应用于实际浇注后，铸坯质量得到明显改善。
As an economic section material, H-beam with its obvious mechanical andfunctional properties has been used in many fields of national economy developmentsince its first appearence. Beam blank is the idealist strand for H-beam production.Rolling H-beam by beam blank has some significant advantages, such as low energyconsumption, less process, high finished product rate and low cost. During beam blankcontinuous casting, there are many surface and inner defects in the strand which can notbe satisfied with the developing requirment of continuous casting technology innowadays. Therefore, studying on the thermo-mechanical behavior of mold and strandand researching on the key factors which shorten the mold service life and cause thedefects during beam blank continuous casting have great significance to the economyand science.
Thermo-mechanical behavior of beam blank mold during continuous casting is oneof the key factors for the mold service life and product quality. In this paperthermo-elastic-plastic creep finite element models of beam blank molds were firstlyestablished, and the numerical method for the simulation of the cyclic process ofheating, casting and cooling were carried out. The user defined subroutines in ABAQUSwere developed to define the nonlinear material constitutive relationship and boundaryconditions. The distributions of temperature, distortion, and stress across the hot facesas well as the fatigue life of the two molds, the large hole mold and the small hole mold,were numerically simulated, based on which the influences of mold grinding thicknessand cooling water flow were discussed. The results show, there is a notable differencebetween molds with different water slot designs. The distributions of temperature anddistortion of the small hole mold are more uniform than those of the large hole mold,and the peak temperature of the former mold is smaller than that of the later mold.Increasing mold grinding thickness or cooling water flow is benifical for mold toachieve lower peak temperature and uniform temperature and distortion. An improvedwater slot design was proposed and it is superior to those molds by numerical analysis.
It is also important for studying the solidification and distortion of strand duringmold to improve casting process and product quality. For simulating the solidificationand distortion of strand during mold, a method for the application of ferrostatic pressureon the front of solidification was proposed. By means of ABAQUS user defined subrountine UEL, a kind of ferrostatic pressure element shares the same nodes with thestrand element which was used to simulate the ferrostatic pressure on the front ofsolidification, was obtained. By means of GAPCON, the heat transfer between thestrand and mold was carried out. A transient thermo-elastic-plasitc finite element modelwas developed, and the influence of solutes microsegregation on material propertieswas taken into account. The distributions of gap between the strand and mold, strandand mold temperature, strand distortion and stress of two molds were obtained. Theresults show, gap is a key factor for the strand solidification, which must be controlled.The taper should be increased to reduce the gap in the flange tip, owing to the large gapand thin shell thickness.
It is known that the surface temperature of the strand must be carefully controlledin the process because it is a key factor in inducing defects, such as internal and surfacecracks. Therefore, a three dimensional simulation method of moving heat tranferconditions was presented to calculate the solidification process of strand. The userdefined subroutines DFLUX and FLIM in ABAQUS were developed to apply thecomplex heat transfer boundary conditions. Based on the method, the temperaturedistribution of the strand was numerically investigated under original and improvedcooling schemes. The results show, the original cooling scheme could not meet themetallurgical principles of beam blank continuous casting. By the numerical simulationthat the uniformity of transverse surface temperature on cross-sections of the beamblank was improved, and better product quality was obtained after the improved coolingscheme was employed in the steel plant.
引文
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