带钢边部缺陷在轧制过程中的开裂行为研究
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摘要
金属板材被广泛应用于汽车、建筑、家电、石油石化、食品包装以及航空航天等行业,是一种重要的工业基础产品。轧制是生产金属板材的重要方法之一。在轧制过程中,金属材料内部各类缺陷(如夹渣、孔洞、裂纹等)经过扩展、聚合造成板材边部开裂或表面质量下降,严重情况还会导致轧制断带事故,制约了轧制生产的连续性,降低了板材的成材率。目前对于金属材料在轧制条件下断裂行为研究的理论基础还非常薄弱,缺乏完整的理论体系。因此研究轧制过程中缺陷的扩展机理不仅可以为金属材料大塑性流动情况下的断裂失效问题研究提供理论基础,同时对抑制边裂缺陷的产生,减少断带事故有着重要实际意义。
本文在研究轧制过程中带钢边部缺口前缘应力应变场分布的基础上,研究了GTN模型对轧制过程中断裂行为的适用性,利用f参量对轧制过程中边部裂纹的萌生和扩展进行了研究,分析了轧制过程中边部缺陷的开裂行为,并通过试验设计方法中的析因分析和正交试验设计方法分析了轧制工艺参数对边部缺陷开裂行为的影响趋势和耦合影响规律,在此基础上建立一种轧制过程中边部缺陷开裂判定准则,并通过自主设计的边部缺陷在线检测装置进行验证。
论文主要研究内容和结论如下：
(1)带钢边部缺口进入轧制区后,缺口尖端区域等效应力和等效塑性变形峰值均出现在缺口尖端偏向轧制方向一侧,并且随着轧制的进行最大等效应力点随之移动；随着累积压下率的增加,轧制方向分力的最大值始终出现在缺口前缘并且逐渐增加；对于不同尺寸的边部缺口,随着长度的增加,尖端应力集中严重,最大等效塑性应变值随之增加。
(2)通过将GTN损伤模型引入到轧制过程的失效模拟中,对边部缺陷开裂行为进行有限元仿真,仿真结果表明：压下率到达一定程度时,边部缺口前缘开始出现微小裂纹；当缺口被咬入到轧制区后,缺口前侧边由于受到摩擦力的作用运行速度比后侧边快,缺口尖端的轧制方向应力分量迅速增大,导致缺口尖端附近材料内部的微小孔洞开始萌生和聚合,当孔洞的体积百分比达到临界值时便产生微小的裂纹；裂纹首先出现在缺口尖端并沿着与轧制方向呈约45°方向扩展；当压下率进一步增加时,另一条裂纹也在缺口前缘出现并且沿着与轧制方向约成135°的方向扩展。
(3)利用析因分析法和正交试验设计法研究了压下率、张力水平、摩擦系数和轧辊半径等因素对边部缺陷开裂行为的影响规律及影响程度。结果表明压下率和张力是边部裂纹扩展的主要影响因子,摩擦系数和轧辊直径为次要因子,按照影响的显著程度排序依次为：压下率,单位张力,摩擦系数和轧辊直径；其中裂纹长度随着压下率,单位张力和摩擦系数的增大而增加,随着轧辊直径的增加而降低。
(4)建立一种轧制过程边部缺陷开裂判据,该判据考虑了轧制工艺参数以及不同材料性能对临界边部缺陷尺寸的影响,建立了压下率、张力、临界初始边部缺陷尺寸以及平均等效塑性应变的关系。结合自主设计研发的带钢边部缺陷在线检测装置对带钢边部缺陷进行实时在线检测。结果表明：检测装置阈值设置为计算值时,检测装置获得的报警数与实测边裂数吻合较好,累计报警数的增长率与累计实测边裂数增长率一致；阈值设置过大会导致大量超过临界尺寸的缺陷通过检测而没有触发报警；阈值设置过小将导致检测条件过于“苛刻”而产生较多误报警。通过在线边部缺陷检测证明了所提出的轧制断裂判据可以准确地对边部缺陷的开裂行为,有效降低了轧制断带和边裂缺陷的发生。
The steel strip, which is one of the important industrial necessities, has been widely used in automotive industry, construction, household appliances, petrochemical, food packaging and aerospace industries. Rolling is the most important procedure in the manufacture of steel strips. During the rolling process, edge cracks and flaws occur due to the growth and coalescence of the inner micro defects, such as inclusions, voids, cracks et.al. These edge cracks and flaws may lead to the fracture of the strip steel or even more serious accidents, which severely reduce the productivity and the yield. At present, the theoretical basis for the fracture behavior of steels under rolling condition is still very weak. Therefore, research of the fracture mechanism of strip steel during rolling process can not only provide a theoretical basis for the study of fracture failures of metallic materials under large plastic flow condition, but also has important practical significance of inhibiting the edge defects and reducing the accidents of strip fracture.
In this study, the stress and strain distribution at the edge notch tip during rolling process were discussed and the GTN damage model was introduced to predict the fracture behaviors of strip steels. The onset of edge cracks has been simulated by using FE method based on the GTN damage model. Factorial design and Taguchi experimental design methods have been proposed to analyze the effects of processing parameters on the formation of edge cracks. Rolling experiments were carried out to validate the simulation results. A simplified fracture criterion under rolling condition has been proposed in terms of the simulation results.
The main study contents and conclusions are listed as follows:
(1) When the edge notch enters into the rolling zone, the maximum equivalent stress and strain appear at the notch tip on the side of deflection in rolling direction. The peak points move during the rolling process but the maximum values maintain constant. With the increasing of the total reduction ratio, the maximum of the crack growth driving force (SI1) increases while the value keeps constant. With the increasing of edge notch length, the stress concentration becomes more severer and the maximum equivalent strain increases.
(2) The finite element simulation was carried out to investigate the initiation of edge cracks by utilizing the GTN damage model. The simulation results show that edge cracks initiate when the total reduction ratio reaches to certain level. When the notch is dragged into the roll gap, the front side of the notch moves faster than the rear one due to the friction force and the stress component along the rolling direction increases rapidly at the notch tip. which is leading to initiation and propagation of the micro voids. Edge cracks format when the void volume fraction reaches to the critical value. The crack firstly appears at the notch tip near the front side and grows along the direction with an angle about45to the rolling direction. As the increasing of reduction ratio, another crack occurs at the rear side of notch tip with135°to the rolling direction.
(3) Factorial design and Taguchi experimental design methods have been proposed to analyze the effects of reduction ratio, tension, work roll diameter and friction coefficient on the formation of edge cracks. Factorial design results show that the rank according to the impact degrees on the crack initiation from high to low is reduction ratio, tension, work roll diameter and friction coefficient. Parametric studies indicated that with the increasing of reduction ratio, friction coefficient and tension, the crack length increases. A bigger work roll is beneficial to restrict the edge crack growth as well.
(4) A simplified fracture criterion under rolling condition has been proposed, which has been verified via rolling tests on the production line by using the device which can detect both the surface and inner edge defects on line. The testing data reveals that it is reasonable for the tandem cold rolling line to set the critical value of defect size as the calculated value. Because under this circumstance the number of defects detecting by device has a good agreement with the number counting at the edge of rolled steel coils. If the critical value is set to be lower, the more wrong alerting signals will generate. Conversely, If the critical value is set to be higher, more defects which can cause edge cracks will pass the detecting device without inducing any alerting signals. The fracture criterion can predict the formation of edge crack during rolling process which is helpful for reducing edge cracks in the real manufacturing process.
本文在研究轧制过程中带钢边部缺口前缘应力应变场分布的基础上,研究了GTN模型对轧制过程中断裂行为的适用性,利用f参量对轧制过程中边部裂纹的萌生和扩展进行了研究,分析了轧制过程中边部缺陷的开裂行为,并通过试验设计方法中的析因分析和正交试验设计方法分析了轧制工艺参数对边部缺陷开裂行为的影响趋势和耦合影响规律,在此基础上建立一种轧制过程中边部缺陷开裂判定准则,并通过自主设计的边部缺陷在线检测装置进行验证。
论文主要研究内容和结论如下：
(1)带钢边部缺口进入轧制区后,缺口尖端区域等效应力和等效塑性变形峰值均出现在缺口尖端偏向轧制方向一侧,并且随着轧制的进行最大等效应力点随之移动；随着累积压下率的增加,轧制方向分力的最大值始终出现在缺口前缘并且逐渐增加；对于不同尺寸的边部缺口,随着长度的增加,尖端应力集中严重,最大等效塑性应变值随之增加。
(2)通过将GTN损伤模型引入到轧制过程的失效模拟中,对边部缺陷开裂行为进行有限元仿真,仿真结果表明：压下率到达一定程度时,边部缺口前缘开始出现微小裂纹；当缺口被咬入到轧制区后,缺口前侧边由于受到摩擦力的作用运行速度比后侧边快,缺口尖端的轧制方向应力分量迅速增大,导致缺口尖端附近材料内部的微小孔洞开始萌生和聚合,当孔洞的体积百分比达到临界值时便产生微小的裂纹；裂纹首先出现在缺口尖端并沿着与轧制方向呈约45°方向扩展；当压下率进一步增加时,另一条裂纹也在缺口前缘出现并且沿着与轧制方向约成135°的方向扩展。
(3)利用析因分析法和正交试验设计法研究了压下率、张力水平、摩擦系数和轧辊半径等因素对边部缺陷开裂行为的影响规律及影响程度。结果表明压下率和张力是边部裂纹扩展的主要影响因子,摩擦系数和轧辊直径为次要因子,按照影响的显著程度排序依次为：压下率,单位张力,摩擦系数和轧辊直径；其中裂纹长度随着压下率,单位张力和摩擦系数的增大而增加,随着轧辊直径的增加而降低。
(4)建立一种轧制过程边部缺陷开裂判据,该判据考虑了轧制工艺参数以及不同材料性能对临界边部缺陷尺寸的影响,建立了压下率、张力、临界初始边部缺陷尺寸以及平均等效塑性应变的关系。结合自主设计研发的带钢边部缺陷在线检测装置对带钢边部缺陷进行实时在线检测。结果表明：检测装置阈值设置为计算值时,检测装置获得的报警数与实测边裂数吻合较好,累计报警数的增长率与累计实测边裂数增长率一致；阈值设置过大会导致大量超过临界尺寸的缺陷通过检测而没有触发报警；阈值设置过小将导致检测条件过于“苛刻”而产生较多误报警。通过在线边部缺陷检测证明了所提出的轧制断裂判据可以准确地对边部缺陷的开裂行为,有效降低了轧制断带和边裂缺陷的发生。
The steel strip, which is one of the important industrial necessities, has been widely used in automotive industry, construction, household appliances, petrochemical, food packaging and aerospace industries. Rolling is the most important procedure in the manufacture of steel strips. During the rolling process, edge cracks and flaws occur due to the growth and coalescence of the inner micro defects, such as inclusions, voids, cracks et.al. These edge cracks and flaws may lead to the fracture of the strip steel or even more serious accidents, which severely reduce the productivity and the yield. At present, the theoretical basis for the fracture behavior of steels under rolling condition is still very weak. Therefore, research of the fracture mechanism of strip steel during rolling process can not only provide a theoretical basis for the study of fracture failures of metallic materials under large plastic flow condition, but also has important practical significance of inhibiting the edge defects and reducing the accidents of strip fracture.
In this study, the stress and strain distribution at the edge notch tip during rolling process were discussed and the GTN damage model was introduced to predict the fracture behaviors of strip steels. The onset of edge cracks has been simulated by using FE method based on the GTN damage model. Factorial design and Taguchi experimental design methods have been proposed to analyze the effects of processing parameters on the formation of edge cracks. Rolling experiments were carried out to validate the simulation results. A simplified fracture criterion under rolling condition has been proposed in terms of the simulation results.
The main study contents and conclusions are listed as follows:
(1) When the edge notch enters into the rolling zone, the maximum equivalent stress and strain appear at the notch tip on the side of deflection in rolling direction. The peak points move during the rolling process but the maximum values maintain constant. With the increasing of the total reduction ratio, the maximum of the crack growth driving force (SI1) increases while the value keeps constant. With the increasing of edge notch length, the stress concentration becomes more severer and the maximum equivalent strain increases.
(2) The finite element simulation was carried out to investigate the initiation of edge cracks by utilizing the GTN damage model. The simulation results show that edge cracks initiate when the total reduction ratio reaches to certain level. When the notch is dragged into the roll gap, the front side of the notch moves faster than the rear one due to the friction force and the stress component along the rolling direction increases rapidly at the notch tip. which is leading to initiation and propagation of the micro voids. Edge cracks format when the void volume fraction reaches to the critical value. The crack firstly appears at the notch tip near the front side and grows along the direction with an angle about45to the rolling direction. As the increasing of reduction ratio, another crack occurs at the rear side of notch tip with135°to the rolling direction.
(3) Factorial design and Taguchi experimental design methods have been proposed to analyze the effects of reduction ratio, tension, work roll diameter and friction coefficient on the formation of edge cracks. Factorial design results show that the rank according to the impact degrees on the crack initiation from high to low is reduction ratio, tension, work roll diameter and friction coefficient. Parametric studies indicated that with the increasing of reduction ratio, friction coefficient and tension, the crack length increases. A bigger work roll is beneficial to restrict the edge crack growth as well.
(4) A simplified fracture criterion under rolling condition has been proposed, which has been verified via rolling tests on the production line by using the device which can detect both the surface and inner edge defects on line. The testing data reveals that it is reasonable for the tandem cold rolling line to set the critical value of defect size as the calculated value. Because under this circumstance the number of defects detecting by device has a good agreement with the number counting at the edge of rolled steel coils. If the critical value is set to be lower, the more wrong alerting signals will generate. Conversely, If the critical value is set to be higher, more defects which can cause edge cracks will pass the detecting device without inducing any alerting signals. The fracture criterion can predict the formation of edge crack during rolling process which is helpful for reducing edge cracks in the real manufacturing process.
引文
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