七斜辊棒材矫直机理论计算及有限元分析
摘要
随着我国国民经济的发展,棒材在工业化建设中发挥着越来越重要的作用,棒材的矫直技术在很大程度上决定着产品的质量水平。许多工厂在矫直棒材时由于缺少理论指导,其工艺参数的确定主要依靠实践经验,这往往造成矫直质量的不稳定,给工业生产带来不利影响。本课题基于七斜辊棒材矫直机的矫直原理,采用理论计算和计算机有限元法相结合的方法对矫直过程进行研究,以指导实际生产。
在对棒材矫直技术的研究过程中,涉及到的相关理论主要有弹塑性理论、材料力学、有限元法、数值分析方法等。
论文综述了近年来国内外矫直理论和矫直技术的发展状况。以金属弹塑性理论为基础分析了七斜辊矫直机的矫直过程,研究了棒材的弯曲变形和弯矩,研究了作用在各辊上的矫直力,推导出了计算矫直力的力学模型,论述了辊型设计的方法,及辊距、倾斜角等参数的选取原则,给出了压下量的计算方法。应用Matlab语言编写可视化软件,使用户只需输入棒材的基本参数便可得出压下量、辊型曲线等数值。
在理论分析和数值计算的基础上,本文应用有限元软件ABAQUS建立了七斜辊矫直机的有限元模型,对有限元模型进行计算求解,并研究了有限元模拟结果,分析棒材应力和应变的变化规律,分析矫直力,验证理论计算的可靠性。
In pace with the development of China's national economy, bar production is playing an increasingly important role in industry construction. Bar straightening technology to a large extent determines the level of product quality. Due to the lack of theoretical guidance, the determine of parameters in bar straightening process relies mainly on practical experience, which often results in instability of the quality, and makes negative impact on industrial manufacture. Based on the straightening principle of seven-roller straightening machine, the straightening process is researched by the method of combining theoretical calculations and computer finite element method (FEM), to guide the actual production.
In the process of researching bar straightening technology, related theories are involved in elastic-plastic theory, mechanics of materials, FEM method and numerical analysis methods.
This paper summarizes the development of straightening theory and straightening technology at home and abroad. Based on metal elastic-plastic theory, this paper analyzes the straightening process of seven-cross-roller straightener, studies the bending deformation and bending moment of the bar, studies the straightening force of each roller, and derives the mechanical model of straightening force. It also discusses design method of the profile of roller, the principle of parameters selected such as roll distance and tilt angle. The method of calculating pressing down displacement is given in this paper. After analyzing the straightening theory, Matlab language is applied to write visualization software, which enables users to simply enter the basic parameters to get the values such as the bar's pressing down displacement,the profile of roller curve and so on.
On the basis of theoretical analysis and numerical calculation, this paper applies FEM software ABAQUS to establish a model of seven-cross-roller straightener, calculates and soles the FEM model, studies the FEM simulation results, analyzes bar variation of stress and strain, verify the reliability of theoretical calculations.
在对棒材矫直技术的研究过程中,涉及到的相关理论主要有弹塑性理论、材料力学、有限元法、数值分析方法等。
论文综述了近年来国内外矫直理论和矫直技术的发展状况。以金属弹塑性理论为基础分析了七斜辊矫直机的矫直过程,研究了棒材的弯曲变形和弯矩,研究了作用在各辊上的矫直力,推导出了计算矫直力的力学模型,论述了辊型设计的方法,及辊距、倾斜角等参数的选取原则,给出了压下量的计算方法。应用Matlab语言编写可视化软件,使用户只需输入棒材的基本参数便可得出压下量、辊型曲线等数值。
在理论分析和数值计算的基础上,本文应用有限元软件ABAQUS建立了七斜辊矫直机的有限元模型,对有限元模型进行计算求解,并研究了有限元模拟结果,分析棒材应力和应变的变化规律,分析矫直力,验证理论计算的可靠性。
In pace with the development of China's national economy, bar production is playing an increasingly important role in industry construction. Bar straightening technology to a large extent determines the level of product quality. Due to the lack of theoretical guidance, the determine of parameters in bar straightening process relies mainly on practical experience, which often results in instability of the quality, and makes negative impact on industrial manufacture. Based on the straightening principle of seven-roller straightening machine, the straightening process is researched by the method of combining theoretical calculations and computer finite element method (FEM), to guide the actual production.
In the process of researching bar straightening technology, related theories are involved in elastic-plastic theory, mechanics of materials, FEM method and numerical analysis methods.
This paper summarizes the development of straightening theory and straightening technology at home and abroad. Based on metal elastic-plastic theory, this paper analyzes the straightening process of seven-cross-roller straightener, studies the bending deformation and bending moment of the bar, studies the straightening force of each roller, and derives the mechanical model of straightening force. It also discusses design method of the profile of roller, the principle of parameters selected such as roll distance and tilt angle. The method of calculating pressing down displacement is given in this paper. After analyzing the straightening theory, Matlab language is applied to write visualization software, which enables users to simply enter the basic parameters to get the values such as the bar's pressing down displacement,the profile of roller curve and so on.
On the basis of theoretical analysis and numerical calculation, this paper applies FEM software ABAQUS to establish a model of seven-cross-roller straightener, calculates and soles the FEM model, studies the FEM simulation results, analyzes bar variation of stress and strain, verify the reliability of theoretical calculations.
引文
1崔甫.矫直原理与矫直机械.北京:冶金工业出版社,2002:233-237,30-90, 266-288
2 Revolving frame machines for the straightening of bars.Wire World International,1997, (19): 6-10
3郭春华,盖茜.管棒材矫直机的发展现状.重工科技,2000,(1) :36-37
4 Ken-ichi Kawai,Makoto Satake,Yukio Inoue etc.Rotary forming for the straightening of tubing.Journal of Material Processing Technology ,1995,(48):135-141
5周永德.试析钢管矫直机的技术发展.宝钢技术,1995,(5) :54-56
6刘浩然.李强.矫直辊辊型分析与管棒材矫直的密切关系.钢管,1995,(4) :27-29
7宋华.弯管辊型矫正辊调角的研究.重型机械,1995,(1) :23-26
8朱美珍,黄雨华,王春香.对向六斜辊管材矫直机压扁压下量研究.包头钢铁学院学报, 1998,(17) :23-25
9赵柄利,赵红雁.斜辊矫直机矫直辊辊形对安装角和接触线长度的影响.燕山大学学报,1998,(22) :165-167
10郑光文.斜辊矫正钢管圆度变化规律的研究.矿冶工程,2003,(23) :89-92
11于凤琴.钢管矫直机力能参数研究.钢管,2008,(5) :26-29
12陈慧敏,赖明道.简析圆形断面材料在矫直过程中的弹塑性弯曲变形.焊管,2000,(23) : 8-10
13高展,刘春旭.钢管压力矫直行程计算公式的理论研究.宝钢技术,2009,(1) :52-53
14胡超大,陈豪敏.棒管材矫直机辊型曲面的设计研究.机械设计与制造,2009,(2) :145- 146
15郑国强.斜辊钢管矫直机调角机构当量计算.重工科技,2007,(1) :54-56
16 Timoshenko S P,Goodier J N.Theory of Elastic(Third Edition) .New York:McGraw-Hill Publication Co,2004:15-18
17王钟仁.弹性与塑性力学基础.哈尔滨:哈尔滨工业大学出版社,1997:20-31
18王海文.轧钢机械设计.北京:机械工业出版社,1983:374-378
19 Beer F P.Mechanics of Materials(Third Edition).北京:清华大学出版社,1983:154-164
20秦世伦.材料力学.成都:四川大学出版社,2008:124-127
21 Ginzburg V B.High-Quality Steel Rolling:Theory and Practice.New York:Marcel Dekker Inc,1993:145-166
22 Kawai,Ken-ichi.Rotary forming for the straightening of tubing.Journal f Materials Processing Technology,1995,(5) :1-2
23崔甫.矫直理论与参数计算.北京:机械工业出版社,1987:48-51
24杨爱珍.微积分.上海:复旦大学出版社,2007:166-180
25陈慧敏.双层卷焊矫直的理论与实验研究.[燕山大学工学硕士学位论文].1998:38-45
26 N K Das Talukder,A N Singh.Mechanics of bar straightening,Part I:Genera analysis of straightening process.ASME J Eng Ind,1991,113(2) :224-227
27马斯基列逊.管材矫直机.北京:机械工业出版社,1979:75-103
28 P P Karasevich,Yu V Savchenko.High accuracy straightening of tubes.Steel in the USSR, 1979:75-103
29 A N Brown.Selection of cross roll straightening machines for rounds and tubes.Iron and Steel International,1973(8) :355-360
30邹家祥.轧钢机械.第3版.北京:冶金工业出版社,2000:354-366
31刘志亮.二辊矫直机力能参数研究.机械工程师,2005,(5):77-78
32宋叶志.Matlab数值分析与应用.北京:机械工业出版社,2009:1-5
33 Richard E Crandall.Mathematica for the Science.Addison-Wesley,1991:2-4
34王沫然.Matlab 5.x与科学计算.北京:清华大学出版社,2000:1-6
35苏金明.MATLAB实用教程[M].北京:清华大学出版社,2005:1
36 Matlab 4.0 with Simulink 1.2.MathWorks,1993:6-13
37原思聪.Matlab语言及机械工程应用[M].北京:机械工业出版社,2008:408-409
38赖兴涛,刘玉文.一种新型的棒材与管材矫直辊辊型的设计方法.宝钢技术,2004, (6):1-3
39宋晓梅,张莹,蔡汉明.Solidworks 2008基础教程.北京:人民邮电出版社,2008:78-79
40梁清香,张根全.有限元与MARC实现[M].北京:机械工业出版社,2003:58-99
41嘉木工作室.ANSYS5.7有限元实例分析教程[M].北京:机械工业出版社,2002:2-4
42 O C Zienkieweicz.The Finite Element Method in Engineering Science. London: Mcgraw-Hill,1971:1-13
43 Marcal P V King.Eliastic-plastic analysis of two-dimensional systems by the finite element method.Int.J.Mech.Sci.:1967,93:147-153
44 Hibble,Marcal,Rice.A finite element formation for problems of large strain and large displacement.Int.J.Solids Struc,1970,64:521-530
45赵腾伦.ABAQUS6.6在机械工程中的应用.北京:水利水电出版社,2007:2-15
46庄茁.基于ABAQUS的有限元分析和应用.北京:清华大学出版社,2009:25
47刘展.ABAQUS6.6基础教程与实例详解.北京:中国水利水电出版社,2008:1-7
48石亦平,周玉蓉.ABAQUS有限元分析实例讲解.北京:机械工业出版社,2006, (2):序言
49 LIU Lizhong,LIU Xianghua,WANG Guodong.Simulation on the Strip Rolling by Dynamic Explicit FEM.Journal of Northeastern University (Natural Science) ,2001,22 (3):327-330
50 SUN Dengyue,ZHOU Huifeng,WANG Guanghui. FEM simulation of Q460 20 # angle beam straightening procedure on nine roll straightener. Proceedings of the 2nd International Conference on Modelling and Simulation, 2009: 348-353
51曹金凤,石亦平.ABAQUS有限元分析常见问题解答.北京:机械工业出版社, 2009: 131-142
52 Reddy J N.An Introduction to the Finite Element Method-Second Edition.McGraw Hill, 1993:121-132
53 C Betegón Biempica,J J del Coz Díaz,P J García Nieto,I Pe?uelas Sánchez.Nonlinear Analysis of Residual Stresses in a Rail Manufacturing Process by FEM.Applied Mathematical Modelling,2009,(33):34-53
54曹鸿德.塑性变形力学基础与轧制原理.北京:机械工业出版社,1981:166-172
55 John R S. Modern straightening machine for pipe,tube, bars and sections. Iron and Steel Engineer,1977,(11):38-45
56 Cook.Charles S.Straightening Operations and Residual Stresses In Tubing. Orlando, FL, USA.. ASM Int, Metals Park, OH, USA,1987,(5):61-68
2 Revolving frame machines for the straightening of bars.Wire World International,1997, (19): 6-10
3郭春华,盖茜.管棒材矫直机的发展现状.重工科技,2000,(1) :36-37
4 Ken-ichi Kawai,Makoto Satake,Yukio Inoue etc.Rotary forming for the straightening of tubing.Journal of Material Processing Technology ,1995,(48):135-141
5周永德.试析钢管矫直机的技术发展.宝钢技术,1995,(5) :54-56
6刘浩然.李强.矫直辊辊型分析与管棒材矫直的密切关系.钢管,1995,(4) :27-29
7宋华.弯管辊型矫正辊调角的研究.重型机械,1995,(1) :23-26
8朱美珍,黄雨华,王春香.对向六斜辊管材矫直机压扁压下量研究.包头钢铁学院学报, 1998,(17) :23-25
9赵柄利,赵红雁.斜辊矫直机矫直辊辊形对安装角和接触线长度的影响.燕山大学学报,1998,(22) :165-167
10郑光文.斜辊矫正钢管圆度变化规律的研究.矿冶工程,2003,(23) :89-92
11于凤琴.钢管矫直机力能参数研究.钢管,2008,(5) :26-29
12陈慧敏,赖明道.简析圆形断面材料在矫直过程中的弹塑性弯曲变形.焊管,2000,(23) : 8-10
13高展,刘春旭.钢管压力矫直行程计算公式的理论研究.宝钢技术,2009,(1) :52-53
14胡超大,陈豪敏.棒管材矫直机辊型曲面的设计研究.机械设计与制造,2009,(2) :145- 146
15郑国强.斜辊钢管矫直机调角机构当量计算.重工科技,2007,(1) :54-56
16 Timoshenko S P,Goodier J N.Theory of Elastic(Third Edition) .New York:McGraw-Hill Publication Co,2004:15-18
17王钟仁.弹性与塑性力学基础.哈尔滨:哈尔滨工业大学出版社,1997:20-31
18王海文.轧钢机械设计.北京:机械工业出版社,1983:374-378
19 Beer F P.Mechanics of Materials(Third Edition).北京:清华大学出版社,1983:154-164
20秦世伦.材料力学.成都:四川大学出版社,2008:124-127
21 Ginzburg V B.High-Quality Steel Rolling:Theory and Practice.New York:Marcel Dekker Inc,1993:145-166
22 Kawai,Ken-ichi.Rotary forming for the straightening of tubing.Journal f Materials Processing Technology,1995,(5) :1-2
23崔甫.矫直理论与参数计算.北京:机械工业出版社,1987:48-51
24杨爱珍.微积分.上海:复旦大学出版社,2007:166-180
25陈慧敏.双层卷焊矫直的理论与实验研究.[燕山大学工学硕士学位论文].1998:38-45
26 N K Das Talukder,A N Singh.Mechanics of bar straightening,Part I:Genera analysis of straightening process.ASME J Eng Ind,1991,113(2) :224-227
27马斯基列逊.管材矫直机.北京:机械工业出版社,1979:75-103
28 P P Karasevich,Yu V Savchenko.High accuracy straightening of tubes.Steel in the USSR, 1979:75-103
29 A N Brown.Selection of cross roll straightening machines for rounds and tubes.Iron and Steel International,1973(8) :355-360
30邹家祥.轧钢机械.第3版.北京:冶金工业出版社,2000:354-366
31刘志亮.二辊矫直机力能参数研究.机械工程师,2005,(5):77-78
32宋叶志.Matlab数值分析与应用.北京:机械工业出版社,2009:1-5
33 Richard E Crandall.Mathematica for the Science.Addison-Wesley,1991:2-4
34王沫然.Matlab 5.x与科学计算.北京:清华大学出版社,2000:1-6
35苏金明.MATLAB实用教程[M].北京:清华大学出版社,2005:1
36 Matlab 4.0 with Simulink 1.2.MathWorks,1993:6-13
37原思聪.Matlab语言及机械工程应用[M].北京:机械工业出版社,2008:408-409
38赖兴涛,刘玉文.一种新型的棒材与管材矫直辊辊型的设计方法.宝钢技术,2004, (6):1-3
39宋晓梅,张莹,蔡汉明.Solidworks 2008基础教程.北京:人民邮电出版社,2008:78-79
40梁清香,张根全.有限元与MARC实现[M].北京:机械工业出版社,2003:58-99
41嘉木工作室.ANSYS5.7有限元实例分析教程[M].北京:机械工业出版社,2002:2-4
42 O C Zienkieweicz.The Finite Element Method in Engineering Science. London: Mcgraw-Hill,1971:1-13
43 Marcal P V King.Eliastic-plastic analysis of two-dimensional systems by the finite element method.Int.J.Mech.Sci.:1967,93:147-153
44 Hibble,Marcal,Rice.A finite element formation for problems of large strain and large displacement.Int.J.Solids Struc,1970,64:521-530
45赵腾伦.ABAQUS6.6在机械工程中的应用.北京:水利水电出版社,2007:2-15
46庄茁.基于ABAQUS的有限元分析和应用.北京:清华大学出版社,2009:25
47刘展.ABAQUS6.6基础教程与实例详解.北京:中国水利水电出版社,2008:1-7
48石亦平,周玉蓉.ABAQUS有限元分析实例讲解.北京:机械工业出版社,2006, (2):序言
49 LIU Lizhong,LIU Xianghua,WANG Guodong.Simulation on the Strip Rolling by Dynamic Explicit FEM.Journal of Northeastern University (Natural Science) ,2001,22 (3):327-330
50 SUN Dengyue,ZHOU Huifeng,WANG Guanghui. FEM simulation of Q460 20 # angle beam straightening procedure on nine roll straightener. Proceedings of the 2nd International Conference on Modelling and Simulation, 2009: 348-353
51曹金凤,石亦平.ABAQUS有限元分析常见问题解答.北京:机械工业出版社, 2009: 131-142
52 Reddy J N.An Introduction to the Finite Element Method-Second Edition.McGraw Hill, 1993:121-132
53 C Betegón Biempica,J J del Coz Díaz,P J García Nieto,I Pe?uelas Sánchez.Nonlinear Analysis of Residual Stresses in a Rail Manufacturing Process by FEM.Applied Mathematical Modelling,2009,(33):34-53
54曹鸿德.塑性变形力学基础与轧制原理.北京:机械工业出版社,1981:166-172
55 John R S. Modern straightening machine for pipe,tube, bars and sections. Iron and Steel Engineer,1977,(11):38-45
56 Cook.Charles S.Straightening Operations and Residual Stresses In Tubing. Orlando, FL, USA.. ASM Int, Metals Park, OH, USA,1987,(5):61-68