三辊限动芯棒连轧管（PQF）成形机理及其虚拟仿真系统
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摘要
无缝钢管是一种重要的经济断面钢材，是国民经济建设的重要原材料之一。连轧钢管是热轧无缝钢管工业生产流程中的关键工序，直接影响终态产品尺寸精度和后继加工。目前，三辊连轧管机组已是近10年来大型无缝钢管生产的主流机型。随着市场国际化和产品竞争的日益激烈，各国钢管生产企业都以不断提高产品质量，扩大产品规格、降低生产成本和开发新产品来提高自身的市场竞争力。因此，开展三辊连轧管轧制过程的基本理论及其仿真技术研究，掌握工件连轧成形规律，预报产品尺寸精度和性能，对进一步优化设备工艺参数、建立产品质量预控系统、实现节能降耗具有重要意义和实用价值。
三辊连轧管轧制过程具有典型的三维非线性、热力耦合和参数时变的特点，是一个非常复杂的多道次孔型轧制过程。为了提高仿真速度，快速制定轧制工艺规程，本文首先对孔型轧制的金属流动特点和几何变形特性进行分析，建立了连轧热力耦合解析模型。通过对三辊连轧管轧制过程传热机理进行分析，采用有限差分法建立传热数学模型，该模型能处理轧制过程中复杂的变形场以及各种热力学边界条件，反映了钢管在连轧过程中的温度变化规律，并利用上限法求得三辊连轧管机组各架功率和力矩，仿真结果与现场实测数据吻合良好。
为了深入研究金属变形机理，确定连轧工艺参数，文中根据三辊连轧管孔型及工艺特点，建立了三辊连轧管成形过程三维有限元模型，分析了宽展规律对产品尺寸精度和钢管横截面积的影响。通过对不同孔型、不同规格产品的系列仿真，研究了宽展规律的影响因素：延伸系数和空隙率对周长系数的影响、延伸系数和减径率对壁厚系数的影响以及张力对宽展规律的影响。利用多元线性回归分析法、BP神经网络以及GA-BP神经网络得到连轧宽展模型，对比某厂实际数据，吻合较好。模型实现了钢管尺寸精度的快速预报，为孔型设计和工艺设定提供了理论指导。
针对无缝钢管在连轧过程中受轧辊孔型、轧辊转速及芯棒速度等多因素影响的特点，研究了三辊连轧管连轧过程中金属的流动规律、变形区前后滑分布的影响因素，建立了连轧变形区前后滑分析模型，为轧制工艺提供速度设定模型，还分析了芯棒限动速度和张力对连轧速度制度的影响。
基于Visual Basic平台，引入CAE参数化技术，并结合MARC二次开发技术，建立了三辊连轧管轧制过程虚拟仿真系统，对连轧钢管的工艺设计、尺寸精度、温度分布、力能参数等进行深入分析。该系统能自动完成模型建立及相关数据传递，预测连轧管成形尺寸精度，分析应力场、应变场、温度场等分布状态与变化方式，能有效缩短新产品开发周期、提高孔型设计可靠性、降低轧机能耗和生产成本，具有很好的实际应用价值。
As a kind of important economical section steels, seamless tube is one of theimportant raw materials in the national economy construction. Continuous rolling is animportant procedure in the industry hot rolling process for seamless steel pipes whichdirectly affect the final product size precision and subsequent processing. Currently, threerolls mandrel pipe mills has been the mainstream mill type of the large seamless steel pipeproduction in the last ten years. With internationalization and increasing competition inproduct market, the steel pipe production enterprises continuously improve its productquality, expand product specifications, reduce production cost and develop new productsto improve their market competitiveness. Therefore, it is of great significance and practicalvalue for further optimizing the process parameters, establishing quality pre-controlsystem, realizing energy saving and consumption reducing to carry out the study on basictheory and simulation of three roll mandrel pipe mill rolling process, master the forminglaw, forecast the product precision and performance.
The rolling process of three roll mandrel pipe mill is a very complex multi-stand passrolling procedure with characteristics of typical three-dimensional nonlinear,thermal-mechanical coupling and parameter time-varying. In order to improve thesimulation speed and formulate the rolling schedule rapidly, metal flow and geometricdeformation are analyzed firstly and the thermo-mechanical coupling analytical model isbuilt in this paper. Based on the heat transfer mechanism analysis, the mathematical modelof heat transfer in the rolling process of three roll mandrel pipe mill is established with thefinite difference method which can deal with the complex deformation field, as well asvarious thermodynamic boundary conditions. Also, the rolling power and torque of eachstand are obtained by the upper bound method. The simulation results show a goodagreement with the measured values.
In order to study the plastic deformation mechanism of the metal intensively andcalculation the rolling technological parameters, a3d finite element model for the rollingprocess is established in this paper according to the roll pass and processing characteristics of the three roll mandrel pipe mill. The effect of the spread regularity on the product sizeprecision and the tube cross-sectional area is also analyzed using this model. Throughseries of simulations for different roll pass and various specification products, theinfluence factors of the spread rule are researched, such as the influence of the elongationcoefficient and the void ratio on the circumference coefficient, the influence of theelongation coefficient and the diameter reducing rate on the wall thickness ratio, as well asthe influence of tension effect on the spread rule. Spread model is obtained using multiplelinear regression analysis method, the BP neural network and GA-BP neural network.Simulation results are in good agreement with the actual plant data. Fast and exactprediction of the steel pipe’s dimensional accuracy is realized which can provide atheoretical guidance for the roll pass designing and the process parameters setting.
The seamless steel pipe is influenced by the roll pass, the roll speed, the mandrelspeed and other factors. Therefore, the metal flow law and the influence factors of theforward-backward slip in the deformation zone during the rolling progress of three rollmandrel pipe mill are studied in the paper. Moreover forward slip model is obtained whichcan provide the speed schedule setting model for rolling technology. Moreover the effectsof the mandrel retaining speed and the tension on the speed schedule are analyzed.
A virtual simulation system for the rolling process of three roll mandrel pipe mill isdeveloped by introducing the CAE parametric technology and combining with thesecondary development technology of MARC in the Visual Basic programming platform,which can carry on deeply analysis of the process design, the pipe dimensional accuracy,the temperature distribution and the mechanics parameters. The system can establish themodel, transfer the related data, predict the pipes dimensional accuracy and analyze thestress field, the strain field, the temperature field distribution and transformation. Thesystem has the very good actual using value which can effectively shorten the new productdevelopment cycle, improve the pass design reliability, reduce the rolling energyconsumption and the production cost.
三辊连轧管轧制过程具有典型的三维非线性、热力耦合和参数时变的特点，是一个非常复杂的多道次孔型轧制过程。为了提高仿真速度，快速制定轧制工艺规程，本文首先对孔型轧制的金属流动特点和几何变形特性进行分析，建立了连轧热力耦合解析模型。通过对三辊连轧管轧制过程传热机理进行分析，采用有限差分法建立传热数学模型，该模型能处理轧制过程中复杂的变形场以及各种热力学边界条件，反映了钢管在连轧过程中的温度变化规律，并利用上限法求得三辊连轧管机组各架功率和力矩，仿真结果与现场实测数据吻合良好。
为了深入研究金属变形机理，确定连轧工艺参数，文中根据三辊连轧管孔型及工艺特点，建立了三辊连轧管成形过程三维有限元模型，分析了宽展规律对产品尺寸精度和钢管横截面积的影响。通过对不同孔型、不同规格产品的系列仿真，研究了宽展规律的影响因素：延伸系数和空隙率对周长系数的影响、延伸系数和减径率对壁厚系数的影响以及张力对宽展规律的影响。利用多元线性回归分析法、BP神经网络以及GA-BP神经网络得到连轧宽展模型，对比某厂实际数据，吻合较好。模型实现了钢管尺寸精度的快速预报，为孔型设计和工艺设定提供了理论指导。
针对无缝钢管在连轧过程中受轧辊孔型、轧辊转速及芯棒速度等多因素影响的特点，研究了三辊连轧管连轧过程中金属的流动规律、变形区前后滑分布的影响因素，建立了连轧变形区前后滑分析模型，为轧制工艺提供速度设定模型，还分析了芯棒限动速度和张力对连轧速度制度的影响。
基于Visual Basic平台，引入CAE参数化技术，并结合MARC二次开发技术，建立了三辊连轧管轧制过程虚拟仿真系统，对连轧钢管的工艺设计、尺寸精度、温度分布、力能参数等进行深入分析。该系统能自动完成模型建立及相关数据传递，预测连轧管成形尺寸精度，分析应力场、应变场、温度场等分布状态与变化方式，能有效缩短新产品开发周期、提高孔型设计可靠性、降低轧机能耗和生产成本，具有很好的实际应用价值。
As a kind of important economical section steels, seamless tube is one of theimportant raw materials in the national economy construction. Continuous rolling is animportant procedure in the industry hot rolling process for seamless steel pipes whichdirectly affect the final product size precision and subsequent processing. Currently, threerolls mandrel pipe mills has been the mainstream mill type of the large seamless steel pipeproduction in the last ten years. With internationalization and increasing competition inproduct market, the steel pipe production enterprises continuously improve its productquality, expand product specifications, reduce production cost and develop new productsto improve their market competitiveness. Therefore, it is of great significance and practicalvalue for further optimizing the process parameters, establishing quality pre-controlsystem, realizing energy saving and consumption reducing to carry out the study on basictheory and simulation of three roll mandrel pipe mill rolling process, master the forminglaw, forecast the product precision and performance.
The rolling process of three roll mandrel pipe mill is a very complex multi-stand passrolling procedure with characteristics of typical three-dimensional nonlinear,thermal-mechanical coupling and parameter time-varying. In order to improve thesimulation speed and formulate the rolling schedule rapidly, metal flow and geometricdeformation are analyzed firstly and the thermo-mechanical coupling analytical model isbuilt in this paper. Based on the heat transfer mechanism analysis, the mathematical modelof heat transfer in the rolling process of three roll mandrel pipe mill is established with thefinite difference method which can deal with the complex deformation field, as well asvarious thermodynamic boundary conditions. Also, the rolling power and torque of eachstand are obtained by the upper bound method. The simulation results show a goodagreement with the measured values.
In order to study the plastic deformation mechanism of the metal intensively andcalculation the rolling technological parameters, a3d finite element model for the rollingprocess is established in this paper according to the roll pass and processing characteristics of the three roll mandrel pipe mill. The effect of the spread regularity on the product sizeprecision and the tube cross-sectional area is also analyzed using this model. Throughseries of simulations for different roll pass and various specification products, theinfluence factors of the spread rule are researched, such as the influence of the elongationcoefficient and the void ratio on the circumference coefficient, the influence of theelongation coefficient and the diameter reducing rate on the wall thickness ratio, as well asthe influence of tension effect on the spread rule. Spread model is obtained using multiplelinear regression analysis method, the BP neural network and GA-BP neural network.Simulation results are in good agreement with the actual plant data. Fast and exactprediction of the steel pipe’s dimensional accuracy is realized which can provide atheoretical guidance for the roll pass designing and the process parameters setting.
The seamless steel pipe is influenced by the roll pass, the roll speed, the mandrelspeed and other factors. Therefore, the metal flow law and the influence factors of theforward-backward slip in the deformation zone during the rolling progress of three rollmandrel pipe mill are studied in the paper. Moreover forward slip model is obtained whichcan provide the speed schedule setting model for rolling technology. Moreover the effectsof the mandrel retaining speed and the tension on the speed schedule are analyzed.
A virtual simulation system for the rolling process of three roll mandrel pipe mill isdeveloped by introducing the CAE parametric technology and combining with thesecondary development technology of MARC in the Visual Basic programming platform,which can carry on deeply analysis of the process design, the pipe dimensional accuracy,the temperature distribution and the mechanics parameters. The system can establish themodel, transfer the related data, predict the pipes dimensional accuracy and analyze thestress field, the strain field, the temperature field distribution and transformation. Thesystem has the very good actual using value which can effectively shorten the new productdevelopment cycle, improve the pass design reliability, reduce the rolling energyconsumption and the production cost.
引文
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