大型组合型钢矫直研究与有限元仿真
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摘要
SL1型电力机车边梁是由压形梁和外侧板焊接形成的组合型型钢,是新型电力机车车箱的主要承重边梁。机车边梁(组合型钢)的精度对机车整体结构、机车各零部件的装配、机车的运行速度等有重要影响。压形梁和外侧板在压制和存放过程中产生变形,两者焊接成组合型钢也存在焊接变形,因此需要对组合型钢进行矫直。
由于组合型钢为大型空心型钢,矫直较大弯曲时,型钢存在压扁的可能,所以矫直存在一定的困难,虽然有经验的理论公式但缺少理论、仿真及实际的有效结合。
本文从组合型钢的结构尺寸和原始弯曲变形出发,根据矫直的理论公式进行了大型组合型钢矫直机的开发。
采用有限元软件ANSYS对等效截面型钢和组合型钢实体进行静压下的仿真研究,并与理论计算的结果相比较。
采用ANSYS/LS-DYNA进行矫直过程的动态有限元仿真,根据型钢的弯曲状态分成单向弯曲和双向弯曲两种情况进行仿真。分析组合型钢在各矫直时刻的压下挠度和等效应力,并取型钢上的典型单元观察矫直全过程中的应力和挠度变化情况。另外分析了型钢腹板与辊子凸缘侧面的间隙对型钢腹板弯曲的影响。动态分析只考虑型钢的旁弯,即二维弯曲状态。
根据矫直的理论公式采用visual basic 6.0编制矫直计算程序,完成矫直力和可调辊压下量的精确计算并确定需要的矫直次数。
SL1 type side beam of electric power engine is a composite beam which welded by formed beam and side plate. It's the main bearing beam of new electric power engine vehicle box. it's important for engine integrated structure、assembly parts and engine run speed. After formed and storage, the formed beam and side plate will distort. After welded two parts together, they also would distort.so the composite beam need roller-straightening.
The composite beam is hollow, after straighten it would stave, so the straightening is difficult.although there is theory formula but without unite of theory formula, simulation and practice.
In this article, the roller-straightening machine design is according to the structure dimension and original distortion of the composite beam, also followed the theory formula of roller-straighten.
The equivalent section beam and the composite beam simulation study of static analysis are using the FEA(finite element analysis) software ANSYS, the simulated result is compared with theory calculation value.
The dynamic simulation of roller-straightening process is using the LS-DYNA software, analysis the distortion and stress of composite beam in different time. Observe the stress and distortion variety in the straightening process by selecting typical element. Also analysis the clearance between composite beam and rollers which will influence the bending of composite beam side plate (side plate of formed beam). The dynamic simulation just considers the side bending which is 2-D bending.
Compiled the calculation program of roller-straightening according to theory formula. Complete the precision calculation of the straightening force and the adjective rollers displacement, confirm the needed straightening times.
由于组合型钢为大型空心型钢,矫直较大弯曲时,型钢存在压扁的可能,所以矫直存在一定的困难,虽然有经验的理论公式但缺少理论、仿真及实际的有效结合。
本文从组合型钢的结构尺寸和原始弯曲变形出发,根据矫直的理论公式进行了大型组合型钢矫直机的开发。
采用有限元软件ANSYS对等效截面型钢和组合型钢实体进行静压下的仿真研究,并与理论计算的结果相比较。
采用ANSYS/LS-DYNA进行矫直过程的动态有限元仿真,根据型钢的弯曲状态分成单向弯曲和双向弯曲两种情况进行仿真。分析组合型钢在各矫直时刻的压下挠度和等效应力,并取型钢上的典型单元观察矫直全过程中的应力和挠度变化情况。另外分析了型钢腹板与辊子凸缘侧面的间隙对型钢腹板弯曲的影响。动态分析只考虑型钢的旁弯,即二维弯曲状态。
根据矫直的理论公式采用visual basic 6.0编制矫直计算程序,完成矫直力和可调辊压下量的精确计算并确定需要的矫直次数。
SL1 type side beam of electric power engine is a composite beam which welded by formed beam and side plate. It's the main bearing beam of new electric power engine vehicle box. it's important for engine integrated structure、assembly parts and engine run speed. After formed and storage, the formed beam and side plate will distort. After welded two parts together, they also would distort.so the composite beam need roller-straightening.
The composite beam is hollow, after straighten it would stave, so the straightening is difficult.although there is theory formula but without unite of theory formula, simulation and practice.
In this article, the roller-straightening machine design is according to the structure dimension and original distortion of the composite beam, also followed the theory formula of roller-straighten.
The equivalent section beam and the composite beam simulation study of static analysis are using the FEA(finite element analysis) software ANSYS, the simulated result is compared with theory calculation value.
The dynamic simulation of roller-straightening process is using the LS-DYNA software, analysis the distortion and stress of composite beam in different time. Observe the stress and distortion variety in the straightening process by selecting typical element. Also analysis the clearance between composite beam and rollers which will influence the bending of composite beam side plate (side plate of formed beam). The dynamic simulation just considers the side bending which is 2-D bending.
Compiled the calculation program of roller-straightening according to theory formula. Complete the precision calculation of the straightening force and the adjective rollers displacement, confirm the needed straightening times.
引文
1.崔甫.矫直理论与参数计算[M],北京：机械工业出版社,1994,1-40
2.刘洪新.辊式矫直机力能参数及其CAD集成方法的研究[D],上海：上海交通大学,2002
3. Cook G, Hansen N E and Trotman E. General Scheme for Automatic Control of Bending Beaming Dynamic Systems[J], Meas and Control,1982,104:173-179
4. Hardt D E, Robert M A and Stelson K A. Closed_Loop Control of a Roll Bending Process Dynamic Systems[J], Meas and Control,1982,102:120-150
5. Hardt D E, Hale M B. Closed_Loop Straightening[J], Annals of Cirp,1984,20:20-80
6. Hale M B and Hart D E. Modeling and Control of a Roll Bending Process[J], IEEE Control systems,1987,50:20-60
7. Lee M Y and Stelson K A. Adaptive Control for a Straightening Process[J], ASME,1984, 10:153-166
8. David Hard,Theresa J,Michael Detal. Real_time Control of Twist deformation [J], CirpAnn, 1987,36:77-180
9. Juen A R. Straightening of circular saw blades[J], Strips Sheet Tubes,1985,2:18-20
10.西安重型机械研究所拉弯矫直机组.国外连续拉弯矫直机发展概况[J],重型机械,1976,64：20-30
11.崔甫.我国首创的复合转毂式矫直机[J],世界金属导报,1991,5：2-6
12.曹自立.电子计算机控制的十七辊2800变断面矫直机研制[J],重型机械,1983,20：1-5
13.吴昌国.西重所开发的高精度管棒材矫直机[J],重型机械,1994,5：10-20
14. SchleinzerG, Fischer FD. Residual stress formation during the roller straightening of Railway rails[J], International Journal of Mechanical Sciences,2001,10:228-229
15. Varney B E, Farris T N. Mechanics of roller straightening Mechanical Working and Steel Processing Conference Proceedings [J], ASME,1997,10:1111-1121
16. Volegov IF, Polyakov A P, Kolmogorov S V. Mathematical model of rail straightening and experimental estimation of its adequacy [J], Journal of Materials Processing Technology, 1994,40:213-218
17.王仲仁,汪涛,贺毓辛等译.金属塑性变形理论[M],机械工业出版社,1992,10-40
18.玉野敏隆.定常变形問题の有限要素法こよゐ解析[J],塑性と加工,1973,14(153)： 766-769
19. Liu C, Hartley P, Sturgess C E N,et.al. Finite-element modeling of deformation and spread in slab rolling[J], International Journal of Mechanical Sciences,1987,29(4): 271-283
20.杜凤山,刘才,连家创.轧制过程中板形控制的计算机模拟[J],机械工程学报,1992,28(6)：9-13
21.朱有利,龚永平,康永林.带材异步冷轧时大变形弹塑性有限元模拟和实验[J],钢铁研究学报,1996,8(5)：22-25
22.机车工艺资料.型钢调直产品规格[M],大连机车车辆有限公司,2006,1-10
23.中国机械工程学会焊接学会.焊接手册-焊接结构[M],北京：机械工业出版社,2001,20-100
24.张小平,秦建平主编.轧制理论[M],冶金工业出版社,2006,39-47
25.邹家祥,施东成,轧钢机械理论与机构设计[M],北京：冶金工业出版社,1996,20-80
26.崔甫.矫直原理与矫直机械[M],北京：冶金工业出版社,2002,10-150
27.刘鸿文.材料力学[M],高等教育出版社,2002,210-222
28.崔甫,施东成.矫直机压弯量计算法的探讨[J],冶金设备,1999,2：1-6
29.吴宗泽.机械零件设计手册[M],机械工业出版社,2004,100-300
30.江耕华等.机械传动设计手册[M],煤炭工业出版社,1992,12-50
31.孙志礼,冷兴聚,魏延刚等.机械设计[M],沈阳：东北大学出版社,2000,1-50
32.机械设计手册编委会.机械设计手册[M],北京：机械工业出版社,2004,10-80
33. Mischke, J. Jonca. Simulation of the roller straightening process[J] Journal of Materials Processing Technology,1992,34:265-272
34.万水工作室.ANSYS9.0经典产品基础教程与实例详解[M],北京：中国水利水电出版社,2006,10-150
35.周存龙,徐静,王国栋,刘相华.中厚板在矫直后的残余应力分布分析[J],重型机械,2005,2：22-24
36.周宁.ANSYS机械工程应用实例[M]，中国水利水电出版社,2006,100-130
37.王会刚.H型钢矫直机理及有限元动态仿真研究[D],北京科技大学,2005
38.钟江.基于LS-DYNA的高轧件轧制过程仿真分析与实证研究[D],浙江工业大学,2007
39.尚晓江,苏建宁.ANSYS/LS-DYNA动力分析方法与工程实例[M],中国水利水电出版社,2006,49-150
40.盛和太,喻海良.ANSYS有限元原理与工程应用实例大全[M],清华大学出版社,2007,250-350
41.徐建忠,熊尚武,刘相华.异型扁坯轧制过程的刚塑性有限元分析[J],东北大学学报,2000,21(2)：199-202
42.王春玲.塑性力学[M],中国建材工业出版社,2006,51-62
43.张树兵,戴红,陈哲.Visual Basic 6.0入门与提高[M],清华大学出版社,1999,20-30
44. Ted Coombs Jon Campbell. Visual Basic编程实用大全[M],北京：中国水利水电出版社,2005,20-100
45.张铁,闫家斌.数值分析[M],冶金工业出版社,2001,89-96
46.王勇勤.变辊距矫直机力能参数及矫直规程计算的程序设计[J],重型机械,1999,2：42-45
2.刘洪新.辊式矫直机力能参数及其CAD集成方法的研究[D],上海：上海交通大学,2002
3. Cook G, Hansen N E and Trotman E. General Scheme for Automatic Control of Bending Beaming Dynamic Systems[J], Meas and Control,1982,104:173-179
4. Hardt D E, Robert M A and Stelson K A. Closed_Loop Control of a Roll Bending Process Dynamic Systems[J], Meas and Control,1982,102:120-150
5. Hardt D E, Hale M B. Closed_Loop Straightening[J], Annals of Cirp,1984,20:20-80
6. Hale M B and Hart D E. Modeling and Control of a Roll Bending Process[J], IEEE Control systems,1987,50:20-60
7. Lee M Y and Stelson K A. Adaptive Control for a Straightening Process[J], ASME,1984, 10:153-166
8. David Hard,Theresa J,Michael Detal. Real_time Control of Twist deformation [J], CirpAnn, 1987,36:77-180
9. Juen A R. Straightening of circular saw blades[J], Strips Sheet Tubes,1985,2:18-20
10.西安重型机械研究所拉弯矫直机组.国外连续拉弯矫直机发展概况[J],重型机械,1976,64：20-30
11.崔甫.我国首创的复合转毂式矫直机[J],世界金属导报,1991,5：2-6
12.曹自立.电子计算机控制的十七辊2800变断面矫直机研制[J],重型机械,1983,20：1-5
13.吴昌国.西重所开发的高精度管棒材矫直机[J],重型机械,1994,5：10-20
14. SchleinzerG, Fischer FD. Residual stress formation during the roller straightening of Railway rails[J], International Journal of Mechanical Sciences,2001,10:228-229
15. Varney B E, Farris T N. Mechanics of roller straightening Mechanical Working and Steel Processing Conference Proceedings [J], ASME,1997,10:1111-1121
16. Volegov IF, Polyakov A P, Kolmogorov S V. Mathematical model of rail straightening and experimental estimation of its adequacy [J], Journal of Materials Processing Technology, 1994,40:213-218
17.王仲仁,汪涛,贺毓辛等译.金属塑性变形理论[M],机械工业出版社,1992,10-40
18.玉野敏隆.定常变形問题の有限要素法こよゐ解析[J],塑性と加工,1973,14(153)： 766-769
19. Liu C, Hartley P, Sturgess C E N,et.al. Finite-element modeling of deformation and spread in slab rolling[J], International Journal of Mechanical Sciences,1987,29(4): 271-283
20.杜凤山,刘才,连家创.轧制过程中板形控制的计算机模拟[J],机械工程学报,1992,28(6)：9-13
21.朱有利,龚永平,康永林.带材异步冷轧时大变形弹塑性有限元模拟和实验[J],钢铁研究学报,1996,8(5)：22-25
22.机车工艺资料.型钢调直产品规格[M],大连机车车辆有限公司,2006,1-10
23.中国机械工程学会焊接学会.焊接手册-焊接结构[M],北京：机械工业出版社,2001,20-100
24.张小平,秦建平主编.轧制理论[M],冶金工业出版社,2006,39-47
25.邹家祥,施东成,轧钢机械理论与机构设计[M],北京：冶金工业出版社,1996,20-80
26.崔甫.矫直原理与矫直机械[M],北京：冶金工业出版社,2002,10-150
27.刘鸿文.材料力学[M],高等教育出版社,2002,210-222
28.崔甫,施东成.矫直机压弯量计算法的探讨[J],冶金设备,1999,2：1-6
29.吴宗泽.机械零件设计手册[M],机械工业出版社,2004,100-300
30.江耕华等.机械传动设计手册[M],煤炭工业出版社,1992,12-50
31.孙志礼,冷兴聚,魏延刚等.机械设计[M],沈阳：东北大学出版社,2000,1-50
32.机械设计手册编委会.机械设计手册[M],北京：机械工业出版社,2004,10-80
33. Mischke, J. Jonca. Simulation of the roller straightening process[J] Journal of Materials Processing Technology,1992,34:265-272
34.万水工作室.ANSYS9.0经典产品基础教程与实例详解[M],北京：中国水利水电出版社,2006,10-150
35.周存龙,徐静,王国栋,刘相华.中厚板在矫直后的残余应力分布分析[J],重型机械,2005,2：22-24
36.周宁.ANSYS机械工程应用实例[M]，中国水利水电出版社,2006,100-130
37.王会刚.H型钢矫直机理及有限元动态仿真研究[D],北京科技大学,2005
38.钟江.基于LS-DYNA的高轧件轧制过程仿真分析与实证研究[D],浙江工业大学,2007
39.尚晓江,苏建宁.ANSYS/LS-DYNA动力分析方法与工程实例[M],中国水利水电出版社,2006,49-150
40.盛和太,喻海良.ANSYS有限元原理与工程应用实例大全[M],清华大学出版社,2007,250-350
41.徐建忠,熊尚武,刘相华.异型扁坯轧制过程的刚塑性有限元分析[J],东北大学学报,2000,21(2)：199-202
42.王春玲.塑性力学[M],中国建材工业出版社,2006,51-62
43.张树兵,戴红,陈哲.Visual Basic 6.0入门与提高[M],清华大学出版社,1999,20-30
44. Ted Coombs Jon Campbell. Visual Basic编程实用大全[M],北京：中国水利水电出版社,2005,20-100
45.张铁,闫家斌.数值分析[M],冶金工业出版社,2001,89-96
46.王勇勤.变辊距矫直机力能参数及矫直规程计算的程序设计[J],重型机械,1999,2：42-45