棒材热轧过程三维热力耦合模拟及高硼高速钢辊套复合轧辊研究
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摘要
轧辊是冶金行业最大的消耗件,轧辊消耗成本约为轧钢生产成本的5%-15%,直接关系到钢铁生产企业的生产效率、产品质量与生产成本。目前使用的轧辊大部分为美国30年代开发的高镍铬钼无限冷硬铸铁轧辊,工作层使用完毕后便整体报废。采用辊套式轧辊结构,使轧辊的60%左右可以循环使用,同时工作外层采用高合金材料并进行适当的热处理,从而达到理想的使用效果,大幅提高轧辊使用寿命,降低生产成本。辊套轧辊是冶金行业与轧辊生产企业长期研究的课题,如何提高其安全性与稳定性及选用合适的结构与材料是解决问题的关键所在。
本论文以棒材热轧过程及轧辊为对象系统研究了棒材轧制过程轧件的温度场演变及塑性流变的基本规律,轧辊的温度场演变及热膨胀规律,对组合式轧辊的稳定性进行了研究;分析了轧辊失效原因、轧辊使用的材料及合金元素在高速钢轧辊材料中的作用,并研制成功了一种具有高耐磨性、高强度、高韧性、高耐热性等综合性能指标优异的轧辊材料,研究了双金属复合工艺,采用辊套与辊芯过盈配合的组合式轧辊的技术方案,在此基础上成功研制出了棒材轧制用辊套复合轧辊。现场使用证明,高硼高速钢双金属辊套复合轧辊具有足够的安全稳定性与更高的使用寿命。
研究工作主要包括如下四个部分:
(1)建立了棒材热轧大变形热力耦合三维弹塑性有限元仿真分析模型并确立其热力边界条件,建立热力耦合模型的迭代算法和Marc软件的分析流程以及确立其收敛的判据与条件,为棒材热轧过程的三维仿真分析提供了理论基础。
(2)运用MARC软件对圆棒热轧成品道次进行了非线性三维热力耦合弹塑性有限元模拟,模拟中考虑了几何非线性、材料非线性和边界条件的非线性问题,轧件与轧辊之间的接触换热考虑为与轧制压力、轧件的屈服强度、轧件与轧辊的导热系数、轧件与轧辊的表面形貌等因素的函数关系,得到了轧制过程轧件与轧辊的温度场和应力场的演变规律,其结果对组合式轧辊的结构分析与设计具有指导意义。
(3)提出了采用热量等效的方法来计算轧制过程轧辊辊芯与辊套温度场与应力场,建立了相应的传热方程与热应力分析模型及其边界条件,得到了轧辊的稳态温度分布规律。通过对轧制过程热膨胀、接触应力和等效应力的计算分析,对组合式轧辊的过盈装配方案的可行性进行了论证,并对比分析了不同辊芯直径下的接触应力和等效应力,选取了合适的辊芯直径,论证了组合轧辊在使用过程中的安全稳定性。
(4)通过轧辊失效分析、轧辊材料分析,提出了提高材料导热性与基体红硬性为突破方向的轧辊材料设计思路,将高速钢基体与硼化物硬质相相结合,首次提出“高硼高速钢”材料概念,分析了合金元素在高速钢材料中的作用,研制了一种具有高韧性、高耐磨性及抗热疲劳裂纹性能优良的高硼高速钢轧辊材料,并对材料的主要物理和力学性能进行了测试,研究了双金属复合的铸造工艺,对双金属复合辊套轧辊进行了金相和能谱分析;采用辊套与轧辊过盈联结,研制成功了组合式轧辊。
本论文的研究工作,对棒材轧制组合式轧辊的开发提供理论参考,所研制成功的组合式高硼高速钢复合轧辊具有重要的工程应用前景,对轧辊制造业的技术升级、节能降排、提高钢铁生产企业的经济效益等具有重要意义。同时对棒材轧制工艺控制、棒材轧机的开发和新材料研究具有一定的参考价值。
Milling roll is one of the major expenditure for steel makers, the cost of rolls in rolling process is about 5 to 15 percent of the total production cost. And it has been the major obstacle to productivity, quality and cost since the dawn of iron age. In marketing terms, the indefinite chill cast iron work roll is the main products which has been developed in the 1930s in America. The whole roll is rejected when the worklayer is finished. If we choose the sleeve rolls, about 60 percent of the roll could reused and the ring can make a better performance through materials choosing and heat treatment. Thus, steelmakers throughout the world can find a new way to achieve higher production outputs of higher quality products while holding down costs. For decades the engneers of roll shop and rolling mills have investigated this task. A major obstacle to this quest has been the security and materials.
In this paper, with the steel bar hot rolling process and the rolls as the researching object, the basic laws of the temperature evolement and plastic rheology of the bar, the temperature evolvement and thermal expand of the milling rolls are systematically researched, the effects of alloy elements on the high-speed steel rolls materials are analyzed, and a sort of milling ring material possessing higher wear resistance, higher strength, higher toughness and higher thermal edurance and its bi-metal composite casting process is developed. Based on these, a new collar for bar hot rolling is developed. It is proved by the use of factory that the usage life of this assembled high-speed steel composite roller is higher.
The research mainly includes the following parts:
Firstly, the 3-dimensional thermo-mechanical couple elsto-plastic larger deformation finite elements model for bar hot rolling process, and the boundary conditions for heat transfer and mechanical are established, the iterative arithmetic, the flow for analysis by MARC and its convergent criterion are proposed, so the theory basis for 3-dimension simulating of the bar hot rolling process is established.
Secondly, the 3-dimensional thermo-mechanical couple elsto-plastic finite elements simulateion for the finished stand of bar hot rolling process are accomplised, the problems of geometry nonlinear, materials nonlinear and the boundary nonlinear are considered in the simulation. The contact heat transfer beween the bar and the roller is considered to be a function of rolling pressure, the yielding strength of bar, the conductivity of bar and roller, the surface morphologies, the evolvment of temperature field and stress field are obtained. And the result can direct the structure design and analysising of compound sleeve rolls.
Thirdly, the assembly interference of assembled roller is obtained by experience, and the heat equivalent methods to simulate the temperature field and stress field of the core and sleeve of the roller in the bar hot rolling process is proposed; the heat transfer equation, the model for thermal stress analyzing and its boundary conditions are established, the sta(?)ilize distribution of temperature is obtained. Through the calculating of thermal expandance, contact stress and equivalent stress of roller in the process of bar hot rolling, the feasibility for the interference assembly project to assembled roller is demonstrated, and then the contact stress and equivalent strss under the different diameter of roller core are compared, the appropriate core diameter is obtained. The security of compound sleeve rolls in rolling process is demonstrated.
Fourthly, via the analysis of invalidation and materials of rolls, the idea of materials design was put forward. Rolls could have better performance through improve heat transmition and hot hardness of the roll material. The conception of "HIGH BORON HSS" is first put forward which combine the matrix of HSS and boride. The effects of the alloy elements on the high-steel roll materials is analyzed, a sort of composite roll material with excellent synthesize performance such as higher toughness, higher wear resistance and higher thermal cracking resistance is developed, the physical and mechanics performance of this kinds of material is tested, the inlayed-cast process is developed, and the microsturcture of this bimetallic sleeve is analyzed by microscope. Based on above researches, a kind of high boron HSS compound sleeve roll is manufactured.
The study done in this paper can provide reference for the the control of roll casting technics, design of bar hot roll-caster, and the exploiture of rolls for bar hot rolling, this assembled high-speed steel composite rolls possess tremendous application foreground and important meaning to improve the economical benefit for the bar rolling industrials.
本论文以棒材热轧过程及轧辊为对象系统研究了棒材轧制过程轧件的温度场演变及塑性流变的基本规律,轧辊的温度场演变及热膨胀规律,对组合式轧辊的稳定性进行了研究;分析了轧辊失效原因、轧辊使用的材料及合金元素在高速钢轧辊材料中的作用,并研制成功了一种具有高耐磨性、高强度、高韧性、高耐热性等综合性能指标优异的轧辊材料,研究了双金属复合工艺,采用辊套与辊芯过盈配合的组合式轧辊的技术方案,在此基础上成功研制出了棒材轧制用辊套复合轧辊。现场使用证明,高硼高速钢双金属辊套复合轧辊具有足够的安全稳定性与更高的使用寿命。
研究工作主要包括如下四个部分:
(1)建立了棒材热轧大变形热力耦合三维弹塑性有限元仿真分析模型并确立其热力边界条件,建立热力耦合模型的迭代算法和Marc软件的分析流程以及确立其收敛的判据与条件,为棒材热轧过程的三维仿真分析提供了理论基础。
(2)运用MARC软件对圆棒热轧成品道次进行了非线性三维热力耦合弹塑性有限元模拟,模拟中考虑了几何非线性、材料非线性和边界条件的非线性问题,轧件与轧辊之间的接触换热考虑为与轧制压力、轧件的屈服强度、轧件与轧辊的导热系数、轧件与轧辊的表面形貌等因素的函数关系,得到了轧制过程轧件与轧辊的温度场和应力场的演变规律,其结果对组合式轧辊的结构分析与设计具有指导意义。
(3)提出了采用热量等效的方法来计算轧制过程轧辊辊芯与辊套温度场与应力场,建立了相应的传热方程与热应力分析模型及其边界条件,得到了轧辊的稳态温度分布规律。通过对轧制过程热膨胀、接触应力和等效应力的计算分析,对组合式轧辊的过盈装配方案的可行性进行了论证,并对比分析了不同辊芯直径下的接触应力和等效应力,选取了合适的辊芯直径,论证了组合轧辊在使用过程中的安全稳定性。
(4)通过轧辊失效分析、轧辊材料分析,提出了提高材料导热性与基体红硬性为突破方向的轧辊材料设计思路,将高速钢基体与硼化物硬质相相结合,首次提出“高硼高速钢”材料概念,分析了合金元素在高速钢材料中的作用,研制了一种具有高韧性、高耐磨性及抗热疲劳裂纹性能优良的高硼高速钢轧辊材料,并对材料的主要物理和力学性能进行了测试,研究了双金属复合的铸造工艺,对双金属复合辊套轧辊进行了金相和能谱分析;采用辊套与轧辊过盈联结,研制成功了组合式轧辊。
本论文的研究工作,对棒材轧制组合式轧辊的开发提供理论参考,所研制成功的组合式高硼高速钢复合轧辊具有重要的工程应用前景,对轧辊制造业的技术升级、节能降排、提高钢铁生产企业的经济效益等具有重要意义。同时对棒材轧制工艺控制、棒材轧机的开发和新材料研究具有一定的参考价值。
Milling roll is one of the major expenditure for steel makers, the cost of rolls in rolling process is about 5 to 15 percent of the total production cost. And it has been the major obstacle to productivity, quality and cost since the dawn of iron age. In marketing terms, the indefinite chill cast iron work roll is the main products which has been developed in the 1930s in America. The whole roll is rejected when the worklayer is finished. If we choose the sleeve rolls, about 60 percent of the roll could reused and the ring can make a better performance through materials choosing and heat treatment. Thus, steelmakers throughout the world can find a new way to achieve higher production outputs of higher quality products while holding down costs. For decades the engneers of roll shop and rolling mills have investigated this task. A major obstacle to this quest has been the security and materials.
In this paper, with the steel bar hot rolling process and the rolls as the researching object, the basic laws of the temperature evolement and plastic rheology of the bar, the temperature evolvement and thermal expand of the milling rolls are systematically researched, the effects of alloy elements on the high-speed steel rolls materials are analyzed, and a sort of milling ring material possessing higher wear resistance, higher strength, higher toughness and higher thermal edurance and its bi-metal composite casting process is developed. Based on these, a new collar for bar hot rolling is developed. It is proved by the use of factory that the usage life of this assembled high-speed steel composite roller is higher.
The research mainly includes the following parts:
Firstly, the 3-dimensional thermo-mechanical couple elsto-plastic larger deformation finite elements model for bar hot rolling process, and the boundary conditions for heat transfer and mechanical are established, the iterative arithmetic, the flow for analysis by MARC and its convergent criterion are proposed, so the theory basis for 3-dimension simulating of the bar hot rolling process is established.
Secondly, the 3-dimensional thermo-mechanical couple elsto-plastic finite elements simulateion for the finished stand of bar hot rolling process are accomplised, the problems of geometry nonlinear, materials nonlinear and the boundary nonlinear are considered in the simulation. The contact heat transfer beween the bar and the roller is considered to be a function of rolling pressure, the yielding strength of bar, the conductivity of bar and roller, the surface morphologies, the evolvment of temperature field and stress field are obtained. And the result can direct the structure design and analysising of compound sleeve rolls.
Thirdly, the assembly interference of assembled roller is obtained by experience, and the heat equivalent methods to simulate the temperature field and stress field of the core and sleeve of the roller in the bar hot rolling process is proposed; the heat transfer equation, the model for thermal stress analyzing and its boundary conditions are established, the sta(?)ilize distribution of temperature is obtained. Through the calculating of thermal expandance, contact stress and equivalent stress of roller in the process of bar hot rolling, the feasibility for the interference assembly project to assembled roller is demonstrated, and then the contact stress and equivalent strss under the different diameter of roller core are compared, the appropriate core diameter is obtained. The security of compound sleeve rolls in rolling process is demonstrated.
Fourthly, via the analysis of invalidation and materials of rolls, the idea of materials design was put forward. Rolls could have better performance through improve heat transmition and hot hardness of the roll material. The conception of "HIGH BORON HSS" is first put forward which combine the matrix of HSS and boride. The effects of the alloy elements on the high-steel roll materials is analyzed, a sort of composite roll material with excellent synthesize performance such as higher toughness, higher wear resistance and higher thermal cracking resistance is developed, the physical and mechanics performance of this kinds of material is tested, the inlayed-cast process is developed, and the microsturcture of this bimetallic sleeve is analyzed by microscope. Based on above researches, a kind of high boron HSS compound sleeve roll is manufactured.
The study done in this paper can provide reference for the the control of roll casting technics, design of bar hot roll-caster, and the exploiture of rolls for bar hot rolling, this assembled high-speed steel composite rolls possess tremendous application foreground and important meaning to improve the economical benefit for the bar rolling industrials.
引文
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