55SiMnMo中空钢孔型轧制及冷却过程数值模拟与试验研究
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摘要
近年来随着凿岩机功率的提高和中空钢市场竞争的加剧，以人为本的机械化凿岩方式将逐渐取代手工操作的气动式凿岩机，市场对中空钢产品的质量要求会更高，尤其是需求量巨大的小型钎杆产品。凿岩用小型钎杆工作时，不仅受到岩矿石的剧烈磨损、高压水流或水气混合体流动、以及矿坑水的冲刷腐蚀，还要承受拉压、弯曲、扭转应力以及凿岩机的高频冲击。由于工作条件和受力状况非常复杂，凿岩钎具产品常以疲劳断裂方式失效，国产小钎杆平均使用寿命仅有100米，与国外同类产品质量具有较大差距。
改善中空钢的内在质量是提高钎杆使用寿命的重要手段，而小钎杆内在质量存在问题主要集中在五个方面：材质问题、坯料内壁疏松问题、成品几何尺寸精度问题、轧制和冷却过程微观组织演变控制问题。因此，本文以中空钢轧制和冷却过程为研究对象，将非线性有限元技术与材料微观组织演变理论相结合，对中空钢轧制和冷却过程轧件几何尺寸精度、致密度情况、微观组织演变规律进行数值模拟研究，并结合实验数据验证数值模拟结果的正确性。
利用Gleeble3500热模拟试验机，通过单向热压缩实验获得的55SiMnMo中碳合金钢高温流变应力曲线，分析了55SiMnMo钢高温流变应力行为，并分别利用Arrhenius方程、人工神经网络理论建立了55SiMnMo钢流变应力预测模型。通过对人工神经网络模型和回归模型预测结果的对比，分析了两种流变应力模型的优缺点，为后续的中空钢轧制过程有限元计算奠定了基础。
根据国内某厂“机械钻孔法”中空钢轧制工艺，利用刚塑性有限元软件建立了中空钢轧制过程热、力、微观组织演变及致密度变化的有限元模型，通过数值模拟得到了轧制过程轧件内部宏观场量(温度场、等效应变、等效应变速率)、微观场量(奥氏体晶粒尺寸)和轧件致密度的分布与演变情况。通过对奥氏体晶粒尺寸有限元模拟结果与实验结果的对比，验证了中空钢轧制过程有限元模型的准确性。
利用正交试验法，以有限元软件为计算平台，进行数值模拟，分析了正交试验中各轧制参数对轧件芯孔偏心度和椭圆度的影响规律，利用非线性回归得到了各影响因素与芯孔尺寸精度的关系模型。利用该模型建立了芯孔几何尺寸精度目标函数，结合修正后的宽展公式，以轧件尺寸精度为优化目标，利用遗传算法优化了该厂中空钢轧制孔型系统。并利用铅轧制实验对数值模拟结果进行了验证。
为了研究中空钢轧后冷却过程中的微观组织相变，分析中空钢冷却工艺，利用Formaster-F型膨胀仪进行等温热膨胀试验，测定了55SiMnMo钢等温转变曲线。基于JMAK相变动力学模型和有限元法，对55SiMnMo钢连续冷却过程进行数值模拟，分析了不同冷却速度下微观组织相变情况，并将实验结果与模拟结果进行对比验证了数值模拟的正确性。在此基础上，对中空钢轧后冷却过程进行了数值模拟，得到了中空钢冷却过程温度场、微观组织场，并分析了不同冷却条件对最终轧件微观组织的影响，为冷却工艺制度的优化提供了理论基础。
In recent years, with the improvement of rock drilling machine power and theincreasing market competition of hollow drilling steel, the mechanized drillingmanipulated by people becomes dominant and gradually replaces the pneumatic rock drillmachine operated by manual; the requirements on the quality of hollow drilling steelproduct becomes more higher, especially for the light drilling rod product withtremendous demand. Drilling work with a light drill rod is under the severe wear of the orerock, the erosion corrosion of the high pressure water, water&air mixture and mine water,and also under the tension pressure, bending, torsion and the high-frequency impact of therock drilling machine. Due to the complex working and stress conditions, rock drill tooloften occur fatigue crack. The average drilling depth of domestic light drilling rod is only100metres, which has a big gap with the same products abroad.
One important way to increase the drilling depth of the drilling rod is to improve thequality of the hollow drilling steel. The quality issues of the light drilling rod mainly focuson5aspects: materials, billet internal porosity, finish goods physical dimension accuracy,and microstructure evolution control in both rolling and cooling process. Therefore, takingthe hollow drilling steel rolling and cooling process as study objects, combining thenonlinear finite element technology with the material microstructure evolution theory, thispaper studies the workpiece physical dimension accuracy, density, and microstructureevolution rules by numerical simulation analysis and uses the experimental data to verifythe numerical simulation results.
Using Gleeble3500thermal simulated test machine, the high temperature flow stresscurve of55SiMnMo medium carbon alloy steel was obtained through one-way thermalcompression test, the high temperature flow stress behavior of55SiMnMo steel wasanalyzed, and also the flow stress prediction model of55SiMnMo steel was established byusing the Arrhenius equation and artificial neural network theory. By comparing theprediction results of artificial neural network model and regression model, advantages anddisadvantages of two flow stress models were analyzed, which establishes the foundation for the future finite element calculation of the hollow steel rolling.
Based on the hollow steel rolling process with Mechanical Drilling Method of thedomestic manufacturer, finite element model about the thermal, stress, microstructureevolution and density variation during hollow steel rolling was established by therigid-plastic finite element software; macroscopic fields (temperature field, effective strainand effective stain rate), microscopic fields (austenite grain size) and density distributionand variation of the workpiece were obtained by numerical simulation. With comparisonof the simulated results and experimental data of austenite grain size, the accuracy of finiteelement model during hollow steel rolling was verified.
Adopting the Orthogonal Test method, the rolling parameters’ impact on theeccentricity and ovality of workpiece hole was analyzed base on the numerical modelingwith finite element software, and the relation model of influence factors and hole sizeaccuracy was obtained by nonlinear regression. With the relation model, the objectivefunction of hole size dimensional accuracy was established. Meanwhile combining withthe revised broadening formula, hollow steel rolling pass system of the domesticmanufacturer was optimized by using the genetic algorithm to improve the workpiece sizeaccuracy. In addition, the numerical simulation results were verified through the leadrolling experiment.
In order to study the microstructure phase transformation during hollow steel coolingprocess after rolling, and analyze the cooling process of hollow steel, the isothermalexpansion test was conducted by using the Formaster-F type dilatometer, and the timetemperature transformation (TTT) curve of55SiMnMo steel was measured. Base onJMAK phase transformation kinetics model and finite element method, the continuouscooling process of55SiMnMo steel was simulated numerically, the microstructure phasetransformation with different cooling rates was analyzed, and the numerical simulationaccuracy was verified by comparison of the experimental result and simulated data.Hollow steel cooling process after rolling was also simulated numerically, and thetemperature field and microstructure field during hollow steel cooling process wereobtained; different cooling conditions’ impacts on the microstructure of final workpiecewere also analyzed, which provides the theoretical foundation for the optimization of cooling process.
改善中空钢的内在质量是提高钎杆使用寿命的重要手段，而小钎杆内在质量存在问题主要集中在五个方面：材质问题、坯料内壁疏松问题、成品几何尺寸精度问题、轧制和冷却过程微观组织演变控制问题。因此，本文以中空钢轧制和冷却过程为研究对象，将非线性有限元技术与材料微观组织演变理论相结合，对中空钢轧制和冷却过程轧件几何尺寸精度、致密度情况、微观组织演变规律进行数值模拟研究，并结合实验数据验证数值模拟结果的正确性。
利用Gleeble3500热模拟试验机，通过单向热压缩实验获得的55SiMnMo中碳合金钢高温流变应力曲线，分析了55SiMnMo钢高温流变应力行为，并分别利用Arrhenius方程、人工神经网络理论建立了55SiMnMo钢流变应力预测模型。通过对人工神经网络模型和回归模型预测结果的对比，分析了两种流变应力模型的优缺点，为后续的中空钢轧制过程有限元计算奠定了基础。
根据国内某厂“机械钻孔法”中空钢轧制工艺，利用刚塑性有限元软件建立了中空钢轧制过程热、力、微观组织演变及致密度变化的有限元模型，通过数值模拟得到了轧制过程轧件内部宏观场量(温度场、等效应变、等效应变速率)、微观场量(奥氏体晶粒尺寸)和轧件致密度的分布与演变情况。通过对奥氏体晶粒尺寸有限元模拟结果与实验结果的对比，验证了中空钢轧制过程有限元模型的准确性。
利用正交试验法，以有限元软件为计算平台，进行数值模拟，分析了正交试验中各轧制参数对轧件芯孔偏心度和椭圆度的影响规律，利用非线性回归得到了各影响因素与芯孔尺寸精度的关系模型。利用该模型建立了芯孔几何尺寸精度目标函数，结合修正后的宽展公式，以轧件尺寸精度为优化目标，利用遗传算法优化了该厂中空钢轧制孔型系统。并利用铅轧制实验对数值模拟结果进行了验证。
为了研究中空钢轧后冷却过程中的微观组织相变，分析中空钢冷却工艺，利用Formaster-F型膨胀仪进行等温热膨胀试验，测定了55SiMnMo钢等温转变曲线。基于JMAK相变动力学模型和有限元法，对55SiMnMo钢连续冷却过程进行数值模拟，分析了不同冷却速度下微观组织相变情况，并将实验结果与模拟结果进行对比验证了数值模拟的正确性。在此基础上，对中空钢轧后冷却过程进行了数值模拟，得到了中空钢冷却过程温度场、微观组织场，并分析了不同冷却条件对最终轧件微观组织的影响，为冷却工艺制度的优化提供了理论基础。
In recent years, with the improvement of rock drilling machine power and theincreasing market competition of hollow drilling steel, the mechanized drillingmanipulated by people becomes dominant and gradually replaces the pneumatic rock drillmachine operated by manual; the requirements on the quality of hollow drilling steelproduct becomes more higher, especially for the light drilling rod product withtremendous demand. Drilling work with a light drill rod is under the severe wear of the orerock, the erosion corrosion of the high pressure water, water&air mixture and mine water,and also under the tension pressure, bending, torsion and the high-frequency impact of therock drilling machine. Due to the complex working and stress conditions, rock drill tooloften occur fatigue crack. The average drilling depth of domestic light drilling rod is only100metres, which has a big gap with the same products abroad.
One important way to increase the drilling depth of the drilling rod is to improve thequality of the hollow drilling steel. The quality issues of the light drilling rod mainly focuson5aspects: materials, billet internal porosity, finish goods physical dimension accuracy,and microstructure evolution control in both rolling and cooling process. Therefore, takingthe hollow drilling steel rolling and cooling process as study objects, combining thenonlinear finite element technology with the material microstructure evolution theory, thispaper studies the workpiece physical dimension accuracy, density, and microstructureevolution rules by numerical simulation analysis and uses the experimental data to verifythe numerical simulation results.
Using Gleeble3500thermal simulated test machine, the high temperature flow stresscurve of55SiMnMo medium carbon alloy steel was obtained through one-way thermalcompression test, the high temperature flow stress behavior of55SiMnMo steel wasanalyzed, and also the flow stress prediction model of55SiMnMo steel was established byusing the Arrhenius equation and artificial neural network theory. By comparing theprediction results of artificial neural network model and regression model, advantages anddisadvantages of two flow stress models were analyzed, which establishes the foundation for the future finite element calculation of the hollow steel rolling.
Based on the hollow steel rolling process with Mechanical Drilling Method of thedomestic manufacturer, finite element model about the thermal, stress, microstructureevolution and density variation during hollow steel rolling was established by therigid-plastic finite element software; macroscopic fields (temperature field, effective strainand effective stain rate), microscopic fields (austenite grain size) and density distributionand variation of the workpiece were obtained by numerical simulation. With comparisonof the simulated results and experimental data of austenite grain size, the accuracy of finiteelement model during hollow steel rolling was verified.
Adopting the Orthogonal Test method, the rolling parameters’ impact on theeccentricity and ovality of workpiece hole was analyzed base on the numerical modelingwith finite element software, and the relation model of influence factors and hole sizeaccuracy was obtained by nonlinear regression. With the relation model, the objectivefunction of hole size dimensional accuracy was established. Meanwhile combining withthe revised broadening formula, hollow steel rolling pass system of the domesticmanufacturer was optimized by using the genetic algorithm to improve the workpiece sizeaccuracy. In addition, the numerical simulation results were verified through the leadrolling experiment.
In order to study the microstructure phase transformation during hollow steel coolingprocess after rolling, and analyze the cooling process of hollow steel, the isothermalexpansion test was conducted by using the Formaster-F type dilatometer, and the timetemperature transformation (TTT) curve of55SiMnMo steel was measured. Base onJMAK phase transformation kinetics model and finite element method, the continuouscooling process of55SiMnMo steel was simulated numerically, the microstructure phasetransformation with different cooling rates was analyzed, and the numerical simulationaccuracy was verified by comparison of the experimental result and simulated data.Hollow steel cooling process after rolling was also simulated numerically, and thetemperature field and microstructure field during hollow steel cooling process wereobtained; different cooling conditions’ impacts on the microstructure of final workpiecewere also analyzed, which provides the theoretical foundation for the optimization of cooling process.
引文
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