基于热力耦合的铸轧辊弹性变形数值模拟
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摘要
铝板坯连续铸轧是一种高效、节能、环保工艺,铸轧辊是此系统的核心部件。随着铝板坯连续铸轧工艺向提速与减薄方向发展,铸轧板板形问题日益突出。本文以计算分析铸轧辊弹性变形为研究目标,根据铝板坯铸轧工艺和铸轧辊的特点,通过理论推导、数值仿真、优化拟合和实验验证等手段,结合非线性热力耦合有限元理论,计算分析铸轧辊热力耦合弹性变形,为铸轧辊最佳原始辊型的确定提供依据,为板形控制提供理论参考。全文的研究工作内容和论文结构如下:
针对铝板坯铸轧工艺和铸轧辊的特点,系统地研究了铸轧辊变形计算分析理论的国内外动态,并简单评析。
根据铸轧工艺的特殊性和铸轧辊本身的特点,考虑温度载荷的影响,建立了铸轧辊变形热力耦合计算分析模型;对于铸轧辊与板坯之间存在相对运动和接触问题,设计了动态边界条件的接触判据,采用了轧辊-板坯动态接触边界的自动处理算法,有效地提高了接触搜索的计算效率;在非线性热力耦合有限元理论基础上,耦合分析温度载荷—变形之间的相互影响;体现了铝板坯铸轧过程为材料非线性、几何非线性和接触非线性的大变形。
确定了计算铸轧辊变形关键的边界条件;计算得到了铸轧力分布规律,分析了工艺参数对铸轧力的影响。
分析计算了铸轧辊弹性变形和弹性压扁,得到了原始辊型;分析了工艺参数对铸轧辊弹性变形的影响;为铸轧辊的设计、加工和板形控制提供数据参考、理论依据。
考虑生产实践中可能面对的各种实际问题而进行铸轧辊原始辊型优化和拟合,得到了最佳原始辊型;为铸轧辊的设计、加工提供数据参考、理论依据。
应用非接触测量技术,设计了辊型曲线、铸轧辊变形和温度场的测试方案,现场实测结果与仿真计算结果比较吻合,验证了本文分析计算模型的正确性和模拟方法可行性。
The aluminum strip continuous roll-casting process is a highly efficient, energy saving, and environmental protection technology. Casting-roller is the key assembly of this system.With the development in the fast and ultra thin direction, roll-casting flatness problem becomes prominent gradually. According to the characteristics of roll-casting and its aluminum strip technology, and combined with non-linear thermal coupling finite element theory, calculation and analysis of the roll-casting thermal coupling elastic deformation are done through theoretical analysis, numerical simulation and experimental verification, which provide basis for the determination of the best course roller type,and theoretical reference for the control of the roll shape.
The content and structure of this paper is the following:
According to the characteristics of roll-casting and its aluminum strip technology, the calculating theory domestic and abroad of roller deformation is systematically studied, and is briefly assessed.
The calculation models of the roll-casting thermal coupling elastic deformation in manifold physical fields are established. For the contact mechanical behavior among the roll sets, roll core and slab, in order to enhance the efficiency, adopt the contact search strategy, which combines "determination of the initial contact search area" with "dynamic boundary conditions of access criteria". Based on the finite element theory of non-linear thermal coupling, coupledly analyse the interaction between temperature load and the deformation. Embodies the aluminum slab casting process is a large deformation, with material non-linear, geometry non-linear and contact nonlinear.
The rolling force is calculated, to provide critical data of boundary conditions, and lay foundation for analysis of deformation
Analysis of the elastic deformation and flexibility crushed of the casting roll is done, and the ground roller is obtained. In consideration of various practical problems during production, find the best original roll. And provide data reference and theoretic basis for the design,process and shape-controlling of the casting-roller.
To provide data reference and theoretic basis for the design, process and shape-controlling of the casting-roller, the effect of different parameters on roller deformation is analysed.
In view of the slide and dislocation phenomenon of roller core and roller shell during application and designing, the strain distribution in the binding area between the roller core and cover is analysed, thus provides theoretic data for the application and designing of casting roller.
The measuring plan of the roller profile curve, rolled deformation and temperature field is put forward, and the non-contact measurement is adopted. The experimental values of the scene measuring are very consistent with the simulation values, and validate the correctness and feasibility of the calculation and analysis of this paper.
The whole research work is summed up, and the creative methods of the research are pointed out, at the same time, the future research orientation is established.
针对铝板坯铸轧工艺和铸轧辊的特点,系统地研究了铸轧辊变形计算分析理论的国内外动态,并简单评析。
根据铸轧工艺的特殊性和铸轧辊本身的特点,考虑温度载荷的影响,建立了铸轧辊变形热力耦合计算分析模型;对于铸轧辊与板坯之间存在相对运动和接触问题,设计了动态边界条件的接触判据,采用了轧辊-板坯动态接触边界的自动处理算法,有效地提高了接触搜索的计算效率;在非线性热力耦合有限元理论基础上,耦合分析温度载荷—变形之间的相互影响;体现了铝板坯铸轧过程为材料非线性、几何非线性和接触非线性的大变形。
确定了计算铸轧辊变形关键的边界条件;计算得到了铸轧力分布规律,分析了工艺参数对铸轧力的影响。
分析计算了铸轧辊弹性变形和弹性压扁,得到了原始辊型;分析了工艺参数对铸轧辊弹性变形的影响;为铸轧辊的设计、加工和板形控制提供数据参考、理论依据。
考虑生产实践中可能面对的各种实际问题而进行铸轧辊原始辊型优化和拟合,得到了最佳原始辊型;为铸轧辊的设计、加工提供数据参考、理论依据。
应用非接触测量技术,设计了辊型曲线、铸轧辊变形和温度场的测试方案,现场实测结果与仿真计算结果比较吻合,验证了本文分析计算模型的正确性和模拟方法可行性。
The aluminum strip continuous roll-casting process is a highly efficient, energy saving, and environmental protection technology. Casting-roller is the key assembly of this system.With the development in the fast and ultra thin direction, roll-casting flatness problem becomes prominent gradually. According to the characteristics of roll-casting and its aluminum strip technology, and combined with non-linear thermal coupling finite element theory, calculation and analysis of the roll-casting thermal coupling elastic deformation are done through theoretical analysis, numerical simulation and experimental verification, which provide basis for the determination of the best course roller type,and theoretical reference for the control of the roll shape.
The content and structure of this paper is the following:
According to the characteristics of roll-casting and its aluminum strip technology, the calculating theory domestic and abroad of roller deformation is systematically studied, and is briefly assessed.
The calculation models of the roll-casting thermal coupling elastic deformation in manifold physical fields are established. For the contact mechanical behavior among the roll sets, roll core and slab, in order to enhance the efficiency, adopt the contact search strategy, which combines "determination of the initial contact search area" with "dynamic boundary conditions of access criteria". Based on the finite element theory of non-linear thermal coupling, coupledly analyse the interaction between temperature load and the deformation. Embodies the aluminum slab casting process is a large deformation, with material non-linear, geometry non-linear and contact nonlinear.
The rolling force is calculated, to provide critical data of boundary conditions, and lay foundation for analysis of deformation
Analysis of the elastic deformation and flexibility crushed of the casting roll is done, and the ground roller is obtained. In consideration of various practical problems during production, find the best original roll. And provide data reference and theoretic basis for the design,process and shape-controlling of the casting-roller.
To provide data reference and theoretic basis for the design, process and shape-controlling of the casting-roller, the effect of different parameters on roller deformation is analysed.
In view of the slide and dislocation phenomenon of roller core and roller shell during application and designing, the strain distribution in the binding area between the roller core and cover is analysed, thus provides theoretic data for the application and designing of casting roller.
The measuring plan of the roller profile curve, rolled deformation and temperature field is put forward, and the non-contact measurement is adopted. The experimental values of the scene measuring are very consistent with the simulation values, and validate the correctness and feasibility of the calculation and analysis of this paper.
The whole research work is summed up, and the creative methods of the research are pointed out, at the same time, the future research orientation is established.
引文
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