工业电渣重熔过程电极插入深度数学模型及应用
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摘要
为了预测不同实际电渣重熔过程中合理的电极插入深度,利用Fluent软件中的MHD模型计算得到电渣重熔稳态条件下不同电极插入深度、渣量以及炉渣电导率对应的电阻值,结合实际生产应用的电力制度,建立了工业电渣重熔过程电极插入深度数学模型。通过对比发现,计算值与现场实测值之间的相对误差很小。利用此模型设计了电渣重熔轴承钢所用的渣量及配比,较好地解决了冶炼过程中过度增氧的问题,电渣锭的洁净度明显提高。
In order to predict reasonable electrode immersing depth in different electroslag remelting processes,the corresponding slag pool resistance values for different electrode-immersing depths,slag amounts and slag conductivities under steady-state conditions in the industrial electro-slag remelting process were obtained based on the MHD model in Fluent software. Then combined with the actual factory production regulations,an electrode-immersing depth mathematical model was deduced from the relationship of the voltage,the current,the slag weight and the slag conductivity. The results of the comparison between the calculated values and the measured values showed that the relative error of them was very small. The cleanliness of the steel was obviously improved and the problem of the oxidized Al elements and the excessive increase of oxygen was effectively solved by adjusting the slag system and increasing the slag amount in actual production situations based on the aforementioned model.
In order to predict reasonable electrode immersing depth in different electroslag remelting processes,the corresponding slag pool resistance values for different electrode-immersing depths,slag amounts and slag conductivities under steady-state conditions in the industrial electro-slag remelting process were obtained based on the MHD model in Fluent software. Then combined with the actual factory production regulations,an electrode-immersing depth mathematical model was deduced from the relationship of the voltage,the current,the slag weight and the slag conductivity. The results of the comparison between the calculated values and the measured values showed that the relative error of them was very small. The cleanliness of the steel was obviously improved and the problem of the oxidized Al elements and the excessive increase of oxygen was effectively solved by adjusting the slag system and increasing the slag amount in actual production situations based on the aforementioned model.
引文
[1]李正邦.电渣冶金的发展历程,现状及趋势[J].材料与冶金学报,2011,10(B03):1.(LI Zheng-bang.Development process,current situation and trends of electroslag metallurgy[J].Journal of Materials and Metallurgy,2011,10(B03):1.)
[2]李正邦,傅杰.电渣重熔技术在中国的应用和发展[J].特殊钢,1999,20(2):7.(LI Zheng-bang,FU Jie.Application and development of electroslag remelting technology in China[J].Special Steel,1999,20(2):7.)
[3]李正邦.电渣冶金的理论与实践[M].北京:冶金工业出版社,2011.(LI Zheng-bang.Electroslag Metallurgy Theory and Practice[M].Beijing:Metallurgical Industry Press,2011.)
[4]刘树杰.电极插入深度对电渣重熔过程的重要性[J].材料与冶金学报,2011,10(B01):64.(LIU Shu-jie.Electrode insert into depth for electrical dregs weight rong importance in ESR course[J].Journal of Materials and Metallurgy,2011,10(B01):64.)
[5]孙常亮,周伟基,李涛,等.电渣重熔轴承钢中的硅元素烧损的控制[J].中国冶金,2015,25(6):28.(SUN Chang-liang,ZHOU Wei-ji,LI Tao,et al.Control of silicon element in bearing steel during electroslag remelting[J].China Metallurgy,2015,25(6):28.)
[6]危亚军,郭显胜,黄永钢,等.80 t低频气保恒熔速电渣炉的技术特点及应用[J].中国冶金,2017,27(6):58.(WEI Ya-jun,GUO Xian-sheng,HUANG Yong-gang,et al.Technical feature and application of 80 t ESR furnace with low-frequency,gas protection and constant melting rate[J].China Metallurgy,2017,27(6):58.)
[7]Kharicha A,Ludwig A,Wu M.Droplet formation in small electroslag remelting processes[C]//2011 International Symposium on Liquid Metal Processing and Casting.Nancy:SF2M,2011:113.
[8]Nastac L.Numerical modeling of fluid flow and solidification characteristics of ultrasonically processed A356 alloys[J].ISIJ International,2014,54(8):1830.
[9]Kharicha A,Ludwig A,Wu M.On melting of electrodes during electro-slag remelting[J].ISIJ International,2014,54(7):1621.
[10]Li B,Wang F,Tsukihashi F.Current,magnetic field and joule heating in electroslag remelting processes[J].ISIJ International,2012,52(7):1289.
[11]王晓花,厉英.电渣重熔过程电磁场和温度场数值模拟[J].东北大学学报:自然科学版,2014,35(6):813.(WANG Xiao-hua,LI Ying.Numerical simulation of electromagnetic field and temperature field of ESR[J].Journal of Northeastern University:Natural Science,2014,35(6):813.
[12]李青,王资兴,谢树元.电渣重熔全过程的数学模型开发及过程模拟研究[J].金属学报,2017,53(4):494.(LI Qing,WANG Zi-xing,XIE Shu-yuan.Research on the development of mathematical model of the whole process of electroslag remelting and the process simulation[J].Acta Metallurgica Sinica,2017,53(4):494.)
[13]王晓花,厉英.电渣重熔过程渣池流场数值模拟[J].材料与冶金学报,2014,13(2):133.(WANG Xiao-hua,LI Ying.Numerical simulation of flow field of ESR slag pool[J].Journal of Materials and Metallurgy,2014,13(2):133.)
[14]曲明磊,成国光,李世健,等.2.3 t电渣锭重熔过程电极插入深度的数学模型和应用[J].特殊钢,2017,38(3):5.(QU Ming-lei,CHENG Guo-guang,LI Shi-jian,et al.Mathematical model of electrode immersing depth in 2.3 t electro-slag ingot remelting process and application[J].Special Steel,2017,38(3):5.)
[15]ZHANG G H,CHOU K C.Model for evaluating density of molten slag with optical basicity[J].Journal of Iron and Steel Research,International,2010,17(4):1.
[16]董艳伍,姜周华,李花兵,等.电渣冶金用含氟渣系电导率计算方法[J].材料与冶金学报,2012,11(4):274.(DONG Yan-wu,JIANG Zhou-hua,LI Hua-bing,et al.Conductivity calculation of slag containing fluoride used for electroslag metallurgy[J].Journal of Materials and Metallurgy,2012,11(4):274.)
[17]李星,耿鑫,姜周华,等.电渣重熔高温合金渣系对冶金质量的影响[J].钢铁,2015,50(9):41.(LI Xing,GENG Xin,JIANG Zhou-hua,et al.Influences of slag system on metallurgical quality for high temperature alloy by electroslag remelting[J].Iron and Steel,2015,50(9):41.)
[18]LI S,CHENG G,MIAO Z,et al.Kinetic analysis of aluminum and oxygen variation of G20Cr Ni2Mo bearing steel during industrial electroslag remelting process[J].ISIJ International,2017,57(12):2148.
[2]李正邦,傅杰.电渣重熔技术在中国的应用和发展[J].特殊钢,1999,20(2):7.(LI Zheng-bang,FU Jie.Application and development of electroslag remelting technology in China[J].Special Steel,1999,20(2):7.)
[3]李正邦.电渣冶金的理论与实践[M].北京:冶金工业出版社,2011.(LI Zheng-bang.Electroslag Metallurgy Theory and Practice[M].Beijing:Metallurgical Industry Press,2011.)
[4]刘树杰.电极插入深度对电渣重熔过程的重要性[J].材料与冶金学报,2011,10(B01):64.(LIU Shu-jie.Electrode insert into depth for electrical dregs weight rong importance in ESR course[J].Journal of Materials and Metallurgy,2011,10(B01):64.)
[5]孙常亮,周伟基,李涛,等.电渣重熔轴承钢中的硅元素烧损的控制[J].中国冶金,2015,25(6):28.(SUN Chang-liang,ZHOU Wei-ji,LI Tao,et al.Control of silicon element in bearing steel during electroslag remelting[J].China Metallurgy,2015,25(6):28.)
[6]危亚军,郭显胜,黄永钢,等.80 t低频气保恒熔速电渣炉的技术特点及应用[J].中国冶金,2017,27(6):58.(WEI Ya-jun,GUO Xian-sheng,HUANG Yong-gang,et al.Technical feature and application of 80 t ESR furnace with low-frequency,gas protection and constant melting rate[J].China Metallurgy,2017,27(6):58.)
[7]Kharicha A,Ludwig A,Wu M.Droplet formation in small electroslag remelting processes[C]//2011 International Symposium on Liquid Metal Processing and Casting.Nancy:SF2M,2011:113.
[8]Nastac L.Numerical modeling of fluid flow and solidification characteristics of ultrasonically processed A356 alloys[J].ISIJ International,2014,54(8):1830.
[9]Kharicha A,Ludwig A,Wu M.On melting of electrodes during electro-slag remelting[J].ISIJ International,2014,54(7):1621.
[10]Li B,Wang F,Tsukihashi F.Current,magnetic field and joule heating in electroslag remelting processes[J].ISIJ International,2012,52(7):1289.
[11]王晓花,厉英.电渣重熔过程电磁场和温度场数值模拟[J].东北大学学报:自然科学版,2014,35(6):813.(WANG Xiao-hua,LI Ying.Numerical simulation of electromagnetic field and temperature field of ESR[J].Journal of Northeastern University:Natural Science,2014,35(6):813.
[12]李青,王资兴,谢树元.电渣重熔全过程的数学模型开发及过程模拟研究[J].金属学报,2017,53(4):494.(LI Qing,WANG Zi-xing,XIE Shu-yuan.Research on the development of mathematical model of the whole process of electroslag remelting and the process simulation[J].Acta Metallurgica Sinica,2017,53(4):494.)
[13]王晓花,厉英.电渣重熔过程渣池流场数值模拟[J].材料与冶金学报,2014,13(2):133.(WANG Xiao-hua,LI Ying.Numerical simulation of flow field of ESR slag pool[J].Journal of Materials and Metallurgy,2014,13(2):133.)
[14]曲明磊,成国光,李世健,等.2.3 t电渣锭重熔过程电极插入深度的数学模型和应用[J].特殊钢,2017,38(3):5.(QU Ming-lei,CHENG Guo-guang,LI Shi-jian,et al.Mathematical model of electrode immersing depth in 2.3 t electro-slag ingot remelting process and application[J].Special Steel,2017,38(3):5.)
[15]ZHANG G H,CHOU K C.Model for evaluating density of molten slag with optical basicity[J].Journal of Iron and Steel Research,International,2010,17(4):1.
[16]董艳伍,姜周华,李花兵,等.电渣冶金用含氟渣系电导率计算方法[J].材料与冶金学报,2012,11(4):274.(DONG Yan-wu,JIANG Zhou-hua,LI Hua-bing,et al.Conductivity calculation of slag containing fluoride used for electroslag metallurgy[J].Journal of Materials and Metallurgy,2012,11(4):274.)
[17]李星,耿鑫,姜周华,等.电渣重熔高温合金渣系对冶金质量的影响[J].钢铁,2015,50(9):41.(LI Xing,GENG Xin,JIANG Zhou-hua,et al.Influences of slag system on metallurgical quality for high temperature alloy by electroslag remelting[J].Iron and Steel,2015,50(9):41.)
[18]LI S,CHENG G,MIAO Z,et al.Kinetic analysis of aluminum and oxygen variation of G20Cr Ni2Mo bearing steel during industrial electroslag remelting process[J].ISIJ International,2017,57(12):2148.