板带热连轧轧制力及其设定的研究
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摘要
在计算机控制的板带热连轧生产中，轧制力设定是一个非常重要的环节。它是板带热连轧精轧机组计算机设定模型的核心，其设定精度将直接影响到辊缝的设定，进而影响到穿带的稳定性、板厚精度以及最终的板形质量等等。目前，我国的轧制力设定技术与世界先进水平还存在较大的差距，同时用户对板带材的板厚精度和板形质量也提出了更高的要求。因此，对轧制力设定的研究有着非常重要的理论意义和实用价值。
本文根据宝钢2050热轧厂提供的钢种和数据资料，采用物理模拟和数值模拟相结合的方法，同时引入鲁棒性设计的思想，对板带热连轧轧制规程设定进行了较为系统的研究。
首先，对宝钢提供的钢种195在Gleeble-1500D热力物理模拟试验机上进行高温压缩变形实验，详细的分析了变形温度、变形程度和变形速度对材料变形抗力的影响，并根据实验数据建立了用于有限元模拟的材料变形抗力列表；同时，针对实验中所出现的相变对变形抗力的影响，引入修正因子，对现场中的轧制力进行了修正，从修正结果可以看出，各道次的轧制力精度都有较大幅度的提高，特别是在第三机架，轧制力计算精度提高5.7％。
然后，根据现场轧制参数和实验所得的变形抗力列表，利用DEFORM-2D软件建立了板带热连轧的有限元模型。重点分析了板带热连轧过程温度和轧制力的变化，并将有限元计算的轧制力与宝钢轧制力模型计算值和实测值进行了对比。结果表明，有限元模型的计算值和实测值比较接近，相对误差在5.5％以内。同时，有限元模型的计算精度高于宝钢模型，特别是在第三机架，轧制力计算精度高出4.3％。
最后，根据轧制规程的制定原则和制定方法，制定了传统轧制规程和末架大压下轧制规程两种规程。引入鲁棒性设计的思想，把轧辊偏心看作“噪声”因子，把轧制力的变化看作产品／过程的响应，利用DEFORM-2D对两种轧制规程的热连轧过程进行了有限元数值模拟，对比分析了不同偏心量时两种轧制规程各道次的轧制力变化，并着重分析计算了两种轧制规程的末架在各个偏心量的轧制力波动以及波动范围。结果表明，末架大压下轧制规程的轧制力波动明显小于传统轧制规程的轧制力波动，且前者的轧制力波动范围也小于后者。因此，本文提出的末架大压下轧制规程的轧制力抵抗轧辊偏心干扰的能力更强，具有较好的鲁棒性。
总之，本论文的研究结果对实际生产具有重要的参考价值。
In modern computer controlled hot strip tandem mill production, the preset of rolling load is very important, which is the kernel of computer preset model in hot strip tandem mill. The precision of rolling load will directly affect the preset of roll gap, and then affect the stability of strip threading, the accuracy of strip thickness and the quality of strip shape. Presently, there is still a wide gap between our country and the advanced level of the world in the preset of rolling load. In addition, high demands of the thickness accuracy and shape quality are put forward by customers. Therefore, to research the preset of rolling load is very significant both in theory and practicality.
Based on the steel samples and data which were from the 2050mm hot strip rolling plant of Baoshan steel, this thesis systematically researched the preset of rolling load by using the method which combined numerical simulation with physical simulation and referring to the concept of robustness design.
Firstly, the steel samples were conducted compression deformation experiment at high temperature with Gleeble-1500D thermo-mechanical simulator. After this experiment, the influences of temperature, strain and strain rate on the deformation resistance were detailedly analyzed and the deformation resistance tabular data were obtained. Meanwhile, aimed at the influence of the phase transformation on the deformation resistance, the rolling loads were modified by the modifying factors. The result shows that the accuracy of rolling load at each pass is improved remarkably, especially at the third pass, the accuracy of rolling load upgrades 5.7%.
Secondly, based on the rolling parameters and the deformation resistance tabular data obtained by the experiment, the finite element model of hot strip tandem mill process was established by using DEFORM-2D software. The variation of temperature and rolling loads were mainly analyzed and the simulated values were contrasted with the calculated values of Baoshan steel model and measured values. The result indicates that the simulated rolling forces are closer to the measured values, their errors are less than 5.5%; meanwhile, the accuracy of finite element method is higher than that of Baoshan steel model, especially at the third pass, the accuracy of rolling force is 4.3% higher than that of Baoshan steel model.
Lastly, according to the principle and method of rolling schedule, the traditional schedule and the new rolling schedule with large reduction at the last pass were respectively formulated. Subsequently, regarding the roll eccentricity as the "noise" factor and regarding the variation of rolling load as the response of product by referring to the concept of robustness design, the hot strip tandem mill processes under different rolling schedules were simulated by using DEF0RM-2D software. After the simulation, the variations of rolling loads of different rolling schedules were analyzed and contrasted, and then the fluctuation ranges of rolling loads at the last pass were respectively calculated. The result displays that the fluctuation of rolling load of the new schedule is remarkably less than that of traditional schedule and the fluctuation range of the new one is also less than that of the traditional one. Accordingly, rolling load of the new schedule is able to restrain the influence of roll eccentricity better. In other words, the rolling load of the new schedule has a better robustness.
In a word, the conclusion of this thesis can supply important reference to the hot strip tandem mill production.
本文根据宝钢2050热轧厂提供的钢种和数据资料，采用物理模拟和数值模拟相结合的方法，同时引入鲁棒性设计的思想，对板带热连轧轧制规程设定进行了较为系统的研究。
首先，对宝钢提供的钢种195在Gleeble-1500D热力物理模拟试验机上进行高温压缩变形实验，详细的分析了变形温度、变形程度和变形速度对材料变形抗力的影响，并根据实验数据建立了用于有限元模拟的材料变形抗力列表；同时，针对实验中所出现的相变对变形抗力的影响，引入修正因子，对现场中的轧制力进行了修正，从修正结果可以看出，各道次的轧制力精度都有较大幅度的提高，特别是在第三机架，轧制力计算精度提高5.7％。
然后，根据现场轧制参数和实验所得的变形抗力列表，利用DEFORM-2D软件建立了板带热连轧的有限元模型。重点分析了板带热连轧过程温度和轧制力的变化，并将有限元计算的轧制力与宝钢轧制力模型计算值和实测值进行了对比。结果表明，有限元模型的计算值和实测值比较接近，相对误差在5.5％以内。同时，有限元模型的计算精度高于宝钢模型，特别是在第三机架，轧制力计算精度高出4.3％。
最后，根据轧制规程的制定原则和制定方法，制定了传统轧制规程和末架大压下轧制规程两种规程。引入鲁棒性设计的思想，把轧辊偏心看作“噪声”因子，把轧制力的变化看作产品／过程的响应，利用DEFORM-2D对两种轧制规程的热连轧过程进行了有限元数值模拟，对比分析了不同偏心量时两种轧制规程各道次的轧制力变化，并着重分析计算了两种轧制规程的末架在各个偏心量的轧制力波动以及波动范围。结果表明，末架大压下轧制规程的轧制力波动明显小于传统轧制规程的轧制力波动，且前者的轧制力波动范围也小于后者。因此，本文提出的末架大压下轧制规程的轧制力抵抗轧辊偏心干扰的能力更强，具有较好的鲁棒性。
总之，本论文的研究结果对实际生产具有重要的参考价值。
In modern computer controlled hot strip tandem mill production, the preset of rolling load is very important, which is the kernel of computer preset model in hot strip tandem mill. The precision of rolling load will directly affect the preset of roll gap, and then affect the stability of strip threading, the accuracy of strip thickness and the quality of strip shape. Presently, there is still a wide gap between our country and the advanced level of the world in the preset of rolling load. In addition, high demands of the thickness accuracy and shape quality are put forward by customers. Therefore, to research the preset of rolling load is very significant both in theory and practicality.
Based on the steel samples and data which were from the 2050mm hot strip rolling plant of Baoshan steel, this thesis systematically researched the preset of rolling load by using the method which combined numerical simulation with physical simulation and referring to the concept of robustness design.
Firstly, the steel samples were conducted compression deformation experiment at high temperature with Gleeble-1500D thermo-mechanical simulator. After this experiment, the influences of temperature, strain and strain rate on the deformation resistance were detailedly analyzed and the deformation resistance tabular data were obtained. Meanwhile, aimed at the influence of the phase transformation on the deformation resistance, the rolling loads were modified by the modifying factors. The result shows that the accuracy of rolling load at each pass is improved remarkably, especially at the third pass, the accuracy of rolling load upgrades 5.7%.
Secondly, based on the rolling parameters and the deformation resistance tabular data obtained by the experiment, the finite element model of hot strip tandem mill process was established by using DEFORM-2D software. The variation of temperature and rolling loads were mainly analyzed and the simulated values were contrasted with the calculated values of Baoshan steel model and measured values. The result indicates that the simulated rolling forces are closer to the measured values, their errors are less than 5.5%; meanwhile, the accuracy of finite element method is higher than that of Baoshan steel model, especially at the third pass, the accuracy of rolling force is 4.3% higher than that of Baoshan steel model.
Lastly, according to the principle and method of rolling schedule, the traditional schedule and the new rolling schedule with large reduction at the last pass were respectively formulated. Subsequently, regarding the roll eccentricity as the "noise" factor and regarding the variation of rolling load as the response of product by referring to the concept of robustness design, the hot strip tandem mill processes under different rolling schedules were simulated by using DEF0RM-2D software. After the simulation, the variations of rolling loads of different rolling schedules were analyzed and contrasted, and then the fluctuation ranges of rolling loads at the last pass were respectively calculated. The result displays that the fluctuation of rolling load of the new schedule is remarkably less than that of traditional schedule and the fluctuation range of the new one is also less than that of the traditional one. Accordingly, rolling load of the new schedule is able to restrain the influence of roll eccentricity better. In other words, the rolling load of the new schedule has a better robustness.
In a word, the conclusion of this thesis can supply important reference to the hot strip tandem mill production.
引文
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