铝合金连续铸轧过程流变行为研究及热—力耦合分析
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摘要
双辊铸轧工艺是将快速凝固和变形结合在一起的技术。近年来,由于提高铸轧速度和减薄铸坯厚度具有降低能耗、提高效率和获得良好的带坯力学性能等优点而引起了众多研究者的关注。然而由于铸轧速度的提高和带坯厚度的减薄,铸轧区内金属的流变行为被强化,尤其是对于厚度为2mm量级的带坯,高温固—固流变更为突出,在液—固临界点迅速进入强力轧制,对于这种状态的铸轧区金属流变本构关系的研究几乎还是空白,其间带坯的热力学行为亦难以用传统的规律来分析。为了能准确认识快速铸轧中的一些新现象和建立铝带坯生产过程中最优工艺系统,对极为强化的铸轧过程流变行为基本规律的研究已是十分迫切的需要。
本文结合国家计委产业化前期关键技术与成套装备研制开发项目《铝及铝合金铸轧新技术与设备研制开发》及国家重大基础研究发展规划(“973”项目)《提高铝材质量的基础研究》的子项“瞬态凝固连续大变形能量转换与组织形成多重耦合机理”,对连续铸轧过程材料在瞬态凝固、连续轧制成形过程中的流变行为进行研究,并在此基础上进行热力耦合连续铸轧过程仿真分析。主要包括以下内容:
(1)研制了一套与Gleeble-1500热/力模拟机配套的实验装置进行常规与快速铸轧过程的物理模拟实验研究,分别在10~(-2)—10秒的范围内完成了金属从凝固到流变成形的全过程。同时,对铝合金在液固相变与热形变过程中的流变行为及其影响因素进行了系列的实验研究,获得了铝合金在这一特定过程中组织结构的变化情况。
(2)根据铝合金连续铸轧过程的变形特点,对比分析各种已有的铝合金半固态、固态高温本构模型,基于热力学理论,研究了铝合金铸轧过程中流变应力与变形温度、应变速率和应变等的相互关系,建立了相应的流变本构模型;运用多元线性回归分析方法确定了依赖于温度、应变速率等的本构模型参数,建立了适用于连续铸轧这一特定工况条件下的铝合金流变本构方程,并将其应用于铸轧过程的仿真分析之中,与实验结果进行了比较,证明了所建立的本构模型表达了其真实的流变规律。
(3)基于传热学和有限元基本理论,建立了凝固过程铸坯与轧
Twin roll casting process is a kind of technology which combines fast solidification and continuous deformation progresses together. In recent years, because of improving roll casting speed and decreasing strip thickness can bring many advantanges such as reducing the energy consumption, raising the work efficiency and obtaining good mechanics performance etc., which aroused the attention of numerous researchers. But with the increase of roll casting speed and the decrease of strip thickness, rheological behavior of the metal in the roll casting zone is strengthened, especially when the thickness is reduced to equal to or less than 2mm, high temperature solid-solid rheology phenomenon stands out, roll casting process rapidly enters mighty force rolling at the liquid-solid critical point. Now research of the rheological constitutive relation of the metal in the roll casting zone is nearly a blank, and its thermodynamics behavior is also difficult to be analysed with traditional laws. In order to abtain accurate understanding of some new phenomena in high speed roll casting and set up optimum technologic system in the production process, it has already been a very urgent need to research the basic law of the rheology behavior of the extremely intensive roll casting course.This paper based on the State Planning and Administration Committee Project of Industrialization Prophase Key Technology and Whole Set Equipment Development "New Technology and Equipment Development of Aluminium and its Alloy Roll Casting" and the subitem "Multiple Coupling Mechanism of Energy Transfer and Microstructure Forming during Transient Solidification and Continuous Deformation Process" of State Key Project of Foundamental Research "Foundamental
Research about Improvement the Quality of Aluminum"("973" project), to study the rheological behavior in transient solidification and contiuous rolling process, then to carry on thermo-mechanical coupling simulation of such process. The main contents are as following:(1) A set of experimental equipment which in conjunction with Gleeble-1500 Thermal-Mechanical Simulation Tester is developed to carry on physical analogy experiment research of the normal and high speed roll casting, the whole course from transient solidification to continuous deformation is finished within 10~-2-10 seconds. Meanwhile, a series of simulating experiments on the rheological behavior and its influential factors have been studied, and the changes of microstructure of aluminium alloy during such process have been obtained.(2) On the basis of thermodynamics theory, the deformation characteristics and the physical simulating experimental data of continuous roll casting, and the comparing and analysing of existed various kinds of constitutive models for semi-solid and solid state aluminium alloy, relative constitutive models of continuous roll casting were set up; parameters depend on temperature and strain rate in those models were obtained through multivanable linear regression analysis, a set of constitutive equations applicable for roll casting process were built and then applied to the analyse of roll casting course, the analysis results were compared with the experimental ones, which proved that the established constitutive equations can describe its real rheological rules.(3) Based on heat transfer principle and basic finite element theory, heat transfer finite element mathematics models, which combined casting strip and roll shell together, were set up. Then a kind of analysis method to carry on temperature field simulation was put forward. With ANSYS, a
set of temperature field analysis software system for continuous roll casting process was set up. Through changing relative parameters according to different work conditions (pouring temperature, rolling speed, etc.), then reexecuting the pre-compiled order flow of ANSYS software, relative temperature field simulation results were obtained, which offers the theoretical foundation for parameter design of roll casting course. Meanwhile, the results can provide temperature field information for thermo-mechanical coupled simulation.(4) A set of thermal-mechanical coupled finite element analysis equations were set up based on rigid visco-plasticity finite element principle and mathematics models of temperature field, the influence of thermal contact conductance between casting roller and strip and some other factors, such as metal flows, hot exchanges and deformation energy changing into heat energy etc. were also synthetically considered. A method to conduct multi-nonlinear thermo-mechanical coupling analysis suitable for aluminum strip roll casting process and is explored by carrying out secondary development of ANSYS finite element analysis software, which solved the problem that direct thermo-mechanical coupling anslysis is unable to be used with ANSYS under the condition of both heat mass transfer and phase change phenomenon. The variational rules of temperature field and stress-strain field are obtained in the rheological forming of continuous roll casting; the influencial laws of pouring temperature, rolling speed, length of roll casting zone, etc. on the solidification and deformation behavior were also studied. Simulation results show the thermo-mechanical coupled analyses method, basic equations and programming system basically reflect the real rule of continuous roll casting process and have certain practical value.
(5) A series of experimental tests and analysis of the technologic parameters, such as the pouring temperature, exit temperature of strip, rolling velocity and rolling force on the O1003* 1850mm cast roller of aluminium foil mill of Chengdu and O1030xl 600mm super-thin high speed cast roller of North China Aluminum Company were done, the results of those main technologic parameters were obtained. Meanwhile, Simulating results are compared with experimental ones, both are basically matched, which verified the accuracy of simulation.In sum, this paper combined physical simulation research, heat-conduction, basic theories of rigid visco-plasticity finite element and metal formation, studied the rheology behavior in the course of roll casting. The rheological stress curve and relative regression equations established good foundation for engineering calculation of the deformation behavior and numerical simulation of aluminium roll casting course; a method to conduct multi-nonlinear thermo-mechanical coupled analysis suitable for aluminum strip roll casting process was explored, then a set of software system which combined the thermo-mechanical coupled characteristic of continuous roll casting process was elementarily built, which provided a kind of research method for the development of continous roll casting technology.
本文结合国家计委产业化前期关键技术与成套装备研制开发项目《铝及铝合金铸轧新技术与设备研制开发》及国家重大基础研究发展规划(“973”项目)《提高铝材质量的基础研究》的子项“瞬态凝固连续大变形能量转换与组织形成多重耦合机理”,对连续铸轧过程材料在瞬态凝固、连续轧制成形过程中的流变行为进行研究,并在此基础上进行热力耦合连续铸轧过程仿真分析。主要包括以下内容:
(1)研制了一套与Gleeble-1500热/力模拟机配套的实验装置进行常规与快速铸轧过程的物理模拟实验研究,分别在10~(-2)—10秒的范围内完成了金属从凝固到流变成形的全过程。同时,对铝合金在液固相变与热形变过程中的流变行为及其影响因素进行了系列的实验研究,获得了铝合金在这一特定过程中组织结构的变化情况。
(2)根据铝合金连续铸轧过程的变形特点,对比分析各种已有的铝合金半固态、固态高温本构模型,基于热力学理论,研究了铝合金铸轧过程中流变应力与变形温度、应变速率和应变等的相互关系,建立了相应的流变本构模型;运用多元线性回归分析方法确定了依赖于温度、应变速率等的本构模型参数,建立了适用于连续铸轧这一特定工况条件下的铝合金流变本构方程,并将其应用于铸轧过程的仿真分析之中,与实验结果进行了比较,证明了所建立的本构模型表达了其真实的流变规律。
(3)基于传热学和有限元基本理论,建立了凝固过程铸坯与轧
Twin roll casting process is a kind of technology which combines fast solidification and continuous deformation progresses together. In recent years, because of improving roll casting speed and decreasing strip thickness can bring many advantanges such as reducing the energy consumption, raising the work efficiency and obtaining good mechanics performance etc., which aroused the attention of numerous researchers. But with the increase of roll casting speed and the decrease of strip thickness, rheological behavior of the metal in the roll casting zone is strengthened, especially when the thickness is reduced to equal to or less than 2mm, high temperature solid-solid rheology phenomenon stands out, roll casting process rapidly enters mighty force rolling at the liquid-solid critical point. Now research of the rheological constitutive relation of the metal in the roll casting zone is nearly a blank, and its thermodynamics behavior is also difficult to be analysed with traditional laws. In order to abtain accurate understanding of some new phenomena in high speed roll casting and set up optimum technologic system in the production process, it has already been a very urgent need to research the basic law of the rheology behavior of the extremely intensive roll casting course.This paper based on the State Planning and Administration Committee Project of Industrialization Prophase Key Technology and Whole Set Equipment Development "New Technology and Equipment Development of Aluminium and its Alloy Roll Casting" and the subitem "Multiple Coupling Mechanism of Energy Transfer and Microstructure Forming during Transient Solidification and Continuous Deformation Process" of State Key Project of Foundamental Research "Foundamental
Research about Improvement the Quality of Aluminum"("973" project), to study the rheological behavior in transient solidification and contiuous rolling process, then to carry on thermo-mechanical coupling simulation of such process. The main contents are as following:(1) A set of experimental equipment which in conjunction with Gleeble-1500 Thermal-Mechanical Simulation Tester is developed to carry on physical analogy experiment research of the normal and high speed roll casting, the whole course from transient solidification to continuous deformation is finished within 10~-2-10 seconds. Meanwhile, a series of simulating experiments on the rheological behavior and its influential factors have been studied, and the changes of microstructure of aluminium alloy during such process have been obtained.(2) On the basis of thermodynamics theory, the deformation characteristics and the physical simulating experimental data of continuous roll casting, and the comparing and analysing of existed various kinds of constitutive models for semi-solid and solid state aluminium alloy, relative constitutive models of continuous roll casting were set up; parameters depend on temperature and strain rate in those models were obtained through multivanable linear regression analysis, a set of constitutive equations applicable for roll casting process were built and then applied to the analyse of roll casting course, the analysis results were compared with the experimental ones, which proved that the established constitutive equations can describe its real rheological rules.(3) Based on heat transfer principle and basic finite element theory, heat transfer finite element mathematics models, which combined casting strip and roll shell together, were set up. Then a kind of analysis method to carry on temperature field simulation was put forward. With ANSYS, a
set of temperature field analysis software system for continuous roll casting process was set up. Through changing relative parameters according to different work conditions (pouring temperature, rolling speed, etc.), then reexecuting the pre-compiled order flow of ANSYS software, relative temperature field simulation results were obtained, which offers the theoretical foundation for parameter design of roll casting course. Meanwhile, the results can provide temperature field information for thermo-mechanical coupled simulation.(4) A set of thermal-mechanical coupled finite element analysis equations were set up based on rigid visco-plasticity finite element principle and mathematics models of temperature field, the influence of thermal contact conductance between casting roller and strip and some other factors, such as metal flows, hot exchanges and deformation energy changing into heat energy etc. were also synthetically considered. A method to conduct multi-nonlinear thermo-mechanical coupling analysis suitable for aluminum strip roll casting process and is explored by carrying out secondary development of ANSYS finite element analysis software, which solved the problem that direct thermo-mechanical coupling anslysis is unable to be used with ANSYS under the condition of both heat mass transfer and phase change phenomenon. The variational rules of temperature field and stress-strain field are obtained in the rheological forming of continuous roll casting; the influencial laws of pouring temperature, rolling speed, length of roll casting zone, etc. on the solidification and deformation behavior were also studied. Simulation results show the thermo-mechanical coupled analyses method, basic equations and programming system basically reflect the real rule of continuous roll casting process and have certain practical value.
(5) A series of experimental tests and analysis of the technologic parameters, such as the pouring temperature, exit temperature of strip, rolling velocity and rolling force on the O1003* 1850mm cast roller of aluminium foil mill of Chengdu and O1030xl 600mm super-thin high speed cast roller of North China Aluminum Company were done, the results of those main technologic parameters were obtained. Meanwhile, Simulating results are compared with experimental ones, both are basically matched, which verified the accuracy of simulation.In sum, this paper combined physical simulation research, heat-conduction, basic theories of rigid visco-plasticity finite element and metal formation, studied the rheology behavior in the course of roll casting. The rheological stress curve and relative regression equations established good foundation for engineering calculation of the deformation behavior and numerical simulation of aluminium roll casting course; a method to conduct multi-nonlinear thermo-mechanical coupled analysis suitable for aluminum strip roll casting process was explored, then a set of software system which combined the thermo-mechanical coupled characteristic of continuous roll casting process was elementarily built, which provided a kind of research method for the development of continous roll casting technology.
引文
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