TBM滚刀刀圈轧制成形特性及其变化规律
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摘要
为了研究盘形滚刀刀圈在轧制过程中的变形特点,提高盘形滚刀刀圈的综合性能,本文通过建立刀圈轧制成形的有限元分析模型,研究刀圈在轧制成形过程中等效应力场、等效应变场的演变规律和流线分布特点,并研究刀圈初始轧制温度、主辊摩擦因子和主辊转速对刀圈成形件质量的影响规律。利用D53K-800立式轧环机对刀圈进行轧制试验研究,并对轧制后的刀圈进行金属流线分析。刀圈轧制后金属流线沿其截面几何形状分布,流线光滑且封闭。结果表明:刀圈等效应变随温度变化不大,其值在1. 93左右;主辊摩擦因子过大或过小,刀圈等效应变和应力的平均值和标准差均会增加;主辊转速为2. 632 rad/s时等效应力的标准差最大。
A finite element model of the disc cutter ring in rolling forming is established to analyze the deformation characteristics and improve the comprehensive performance of this cutter ring in the rolling process. This model enables us to examine the evolution law of the effective stress field and effective strain field,as well as the streamline distribution characteristics of the cutter ring in the rolling process. The effects of the initial temperature of the cutter ring,main roller friction factor,and roller speed on the quality of the shaped product are also studied. A rolling test of the cutter ring in D53 K-800 vertical rolling ring machine is conducted and the metal streamline of the cutter ring after rolling is analyzed. After rolling,the metal streamlines of the cutter ring become smooth and closed along its cross section. Results indicate that the effective strain of the cutter ring changes minimally( to a value of approximately 1. 93) with temperature when the friction factor of the main roller is extremely large or extremely small,and the average value and standard deviation of the effective strain and stress of the cutter ring increases. When the main roller speed is 2. 632 rad/s,the standard deviation of effective stress reaches the maximum.
A finite element model of the disc cutter ring in rolling forming is established to analyze the deformation characteristics and improve the comprehensive performance of this cutter ring in the rolling process. This model enables us to examine the evolution law of the effective stress field and effective strain field,as well as the streamline distribution characteristics of the cutter ring in the rolling process. The effects of the initial temperature of the cutter ring,main roller friction factor,and roller speed on the quality of the shaped product are also studied. A rolling test of the cutter ring in D53 K-800 vertical rolling ring machine is conducted and the metal streamline of the cutter ring after rolling is analyzed. After rolling,the metal streamlines of the cutter ring become smooth and closed along its cross section. Results indicate that the effective strain of the cutter ring changes minimally( to a value of approximately 1. 93) with temperature when the friction factor of the main roller is extremely large or extremely small,and the average value and standard deviation of the effective strain and stress of the cutter ring increases. When the main roller speed is 2. 632 rad/s,the standard deviation of effective stress reaches the maximum.
引文
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[15]KIM N,KIM H,JIN Kai. Optimal design to reduce the maximum load in ring rolling process[J]. International journal of precision engineering and manufacturing,2012,13(10):1821-1828.
[16]贺小明,来新民,于忠奇.控制微观组织和材料损伤的锻造工艺多目标优化[J].上海交通大学学报,2007,41(10):1603-1607.HE Xiaoming,LAI Xinmin,YU Zhongqi. Multi-objective optimization of forging process to control the microstructure and damage of material[J]. Journal of Shanghai Jiao Tong University,2007,41(10):1603-1607.
[17]支颖,刘相华,孙涛,等.变厚度轧制过渡区的数学模型[J].哈尔滨工程大学学报,2017,38(4):602-609.ZHI Yin,LIU Xianghua,SUN Tao,et al. Investigation of mathematical model for the transition zone of tailor rolled blank for variable gauge rolling[J]. Journal of Harbin Engineering University,2017,38(4):602-609.
[18]ZHOU G,HUA L,QIAN D S. 3D coupled thermo-mechanical FE analysis of roll size effects on the radial-axial ring rolling process[J]. Computational materials science,2011,50(3):911-924.
[2]施虎,杨华勇,龚国芳,等.盾构掘进机关键技术及模拟试验台现状与展望[J].浙江大学学报(工学版),2013,47(5):741-749.SHI Hu,YANG Huayong,GONG Guofang,et al. Key technologies of shield tunneling machine and present status and prospect of test rigs for tunneling simulation[J]. Journal of Zhejiang university(engineering science),2013,47(5):741-749.
[3]WANG Lihui,KANG Yilan,ZHAO Xiangjun,et al. Disc cutter wear prediction for a hard rock TBM cutterhead based on energy analysis[J]. Tunnelling and&underground space technology incorporating trenchless technology research,2015,50:324-333.
[4]邹甜,华林,韩星会.环件热轧全过程微观组织演化数值模拟和试验研究[J].机械工程学报,2014,50(16):97-103.ZOU Tian,HUA Lin,Han Xinghui. Simulation and experiment study on the microstructure evolution during the whole hot ring rolling process[J]. Journal of mechanical engineering,2014,50(16):97-103.
[5]GIORLEO L,GIARDINI C,CERETTI E. Validation of hot ring rolling industrial process 3D simulation[J]. International journal of material forming,2013,6(1):145-152.
[6]LI Lianjie J,LUO Xiaodong D,ZHU Yongxiang X. Effects of rotational speed of driver roll on hot ring rolling of 6061aluminum alloy by 3D FE simulation[J]. Advanced materials research,2013,773:309-315.
[7]丁敬国,曲丽丽,胡贤磊,等.钢锭楔形轧制法在特厚板宽度控制中的应用[J].哈尔滨工程大学学报,2013,34(7):924-928.DING Jingguo,QU Lili,HU Xianlei,et al. Application of ingot wedge rolling method in ultra-heavy plate width control[J]. Journal of Harbin Engineering University,2013,34(7):924-928.
[8]QIAN Dongsheng,PAN Yan. 3D coupled macro-microscopic finite element modelling and simulation for combined blank-forging and rolling process of alloy steel large ring[J]. Computational materials science,2013,70:24-36.
[9]QIAN Dongsheng,ZHANG Zhiqiang,HUA Lin. An advanced manufacturing method for thick-wall and deepgroove ring-combined ring rolling[J]. Journal of materials processing technology,2013,213(8):1258-1267.
[10]ANJAMI N,BASTI A. Investigation of rolls size effects on hot ring rolling process by coupled thermo-mechanical3D-FEA[J]. Journal of materials processing technology,2010,210(10):1364-1377.
[11]李永堂,齐会萍,付建华,等. 42CrMo钢铸造环坯辗扩成形理论与工艺分析[J].机械工程学报,2014,50(2):77-85.LI Yongtang,QI Huiping,FU Jianhua,et al. Theoretical and process analyses on the cast-blank rolling forming of42CrMo bearing rings[J]. Journal of mechanical engineering,2014,50(2):77-85.
[12]PARVIZI A,ABRINIA K,SALIMI M. Slab analysis of ring rolling assuming constant shear friction[J]. Journal of materials engineering and&performance,2011,20(9):1505-1511.
[13]PARVIZI A, ABRINIA K. A two dimensional upper bound analysis of the ring rolling process with experimental and FEM verifications[J]. International journal of mechanical sciences,2014,79(1):176-181.
[14]ZHU Xinglin,LIU Dong,YANG Yanhui,et al. Optimization on cooperative feed strategy for radial-axial ring rolling process of Inco718 alloy by RSM and FEM[J]. Chinese journal of aeronautics,2016,29(3):831-842.
[15]KIM N,KIM H,JIN Kai. Optimal design to reduce the maximum load in ring rolling process[J]. International journal of precision engineering and manufacturing,2012,13(10):1821-1828.
[16]贺小明,来新民,于忠奇.控制微观组织和材料损伤的锻造工艺多目标优化[J].上海交通大学学报,2007,41(10):1603-1607.HE Xiaoming,LAI Xinmin,YU Zhongqi. Multi-objective optimization of forging process to control the microstructure and damage of material[J]. Journal of Shanghai Jiao Tong University,2007,41(10):1603-1607.
[17]支颖,刘相华,孙涛,等.变厚度轧制过渡区的数学模型[J].哈尔滨工程大学学报,2017,38(4):602-609.ZHI Yin,LIU Xianghua,SUN Tao,et al. Investigation of mathematical model for the transition zone of tailor rolled blank for variable gauge rolling[J]. Journal of Harbin Engineering University,2017,38(4):602-609.
[18]ZHOU G,HUA L,QIAN D S. 3D coupled thermo-mechanical FE analysis of roll size effects on the radial-axial ring rolling process[J]. Computational materials science,2011,50(3):911-924.