φ8-32mm矫直机机架强度分析及工作状态仿真
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摘要
近年来钢铁行业蓬勃发展,工业中对高精度圆材的需求急剧上升,但圆材在轧制、锻造、拉拔等加工过程中由于外力作用及加热冷却不均匀,或运输堆放等原因,产生了不同程度的弯曲和歪扭,或内部存在残余应力,影响成品质量,这样就需要在生产中通过矫直来消除这些缺陷。二斜辊矫直机作为棒材的精矫装备,其机架在工作状态下的强度与刚度是决定矫直精度的关键因素之一,直接影响棒材的质量和成材率。
本选题来源于宝钢实际项目φ8-32mm二辊棒材矫直机,由于矫直力的理论计算值偏小,而最大矫直力的设计与计算则对棒材的矫直直径范围有着重要的影响,发现在实际矫直中,对矫直范围内较粗的棒材矫直效果并不是很理想,甚至出现压下装置被顶出的现象。本文根据现场试矫情况以及三曲率力学模型,重新提出了适合于本台矫直机的等曲率反弯辊形的矫直力计算力学模型计算等曲率反弯辊形的最大矫直力,通过矫直机solidworks三维建模并通过ANSYS有限元分析软件及动力学分析软件ANSYS/LS-DYNA的仿真获得一种可靠的最大矫直力数值,并以此为依据对矫直机机架重新进行了刚度强度一系列的分析。
本文通过仿真得出最大矫直力,解决的实际矫直中遇到的矫直力偏小的问题。通过对预应力机架刚强度分析及ANSYS静态受力分析,得到应力位移分布规律,减小机架变形对辊缝的影响,提高了矫直精度的稳定性。
In recent years, the development of iron and steel industry is vigorous, and the demand for round-steel is rising sharply. But in the process of rolling, forging and drawing, due to forcing, uneven cooling and heating or transportation and stacking, round-steel will produce bending and distortion in different degree, or internal residual stress, which will affect the quality of finished products. Therefore, these defects are necessary to be eliminated in production via straightening. The cross-roll straightener is a finishing equipment straightening the rods. The intensity and the rigidity of the straightening machine rack decides the precision of straightening precision in active status, immediate influence the quality of rods and bars and the rate of yield.
This topic originates from the participation Baoshan Steel CorporationΦ8-32mm two roller rods and bars straightening machine project, because the theory predicted value of the straightening strength is small, but the design and the computation of the biggest straightening strength have the important influence to the tube rods and bars' straightening diameter scope. The straightening scope in the thick rods and bars straightening effect is not very ideal in actual straightening, even presents the phenomenon that the holding-down was went against. This article according to the situation of rectifying as well as three curvature mechanical model, proposed mechanical model suits curvature inflection roller shape in this straightening machine, and computations biggest straightening strength of this mechanical model. Through three dimensional modelling of the straightening machine by solidworks and simulation by the finite element analysis software ANSYS and dynamics analysis software ANSYS/LS-DY NA, the article obtains a value of reliable biggest straightening strength, and has carried on a series of analyses of the rigidity and intensity about the straightening machine.
This article obtains the biggest straightening strength through the simulation, the straightening strength small question which in the solution actual straightening meets. Through to the pre-stressed rack just the strength analysis and the ANSYS static state stress analysis, obtained the stress displacement to distribute the rule, reduced the stand stretch to the roller seam influence, enhanced the straightening precision stability.
本选题来源于宝钢实际项目φ8-32mm二辊棒材矫直机,由于矫直力的理论计算值偏小,而最大矫直力的设计与计算则对棒材的矫直直径范围有着重要的影响,发现在实际矫直中,对矫直范围内较粗的棒材矫直效果并不是很理想,甚至出现压下装置被顶出的现象。本文根据现场试矫情况以及三曲率力学模型,重新提出了适合于本台矫直机的等曲率反弯辊形的矫直力计算力学模型计算等曲率反弯辊形的最大矫直力,通过矫直机solidworks三维建模并通过ANSYS有限元分析软件及动力学分析软件ANSYS/LS-DYNA的仿真获得一种可靠的最大矫直力数值,并以此为依据对矫直机机架重新进行了刚度强度一系列的分析。
本文通过仿真得出最大矫直力,解决的实际矫直中遇到的矫直力偏小的问题。通过对预应力机架刚强度分析及ANSYS静态受力分析,得到应力位移分布规律,减小机架变形对辊缝的影响,提高了矫直精度的稳定性。
In recent years, the development of iron and steel industry is vigorous, and the demand for round-steel is rising sharply. But in the process of rolling, forging and drawing, due to forcing, uneven cooling and heating or transportation and stacking, round-steel will produce bending and distortion in different degree, or internal residual stress, which will affect the quality of finished products. Therefore, these defects are necessary to be eliminated in production via straightening. The cross-roll straightener is a finishing equipment straightening the rods. The intensity and the rigidity of the straightening machine rack decides the precision of straightening precision in active status, immediate influence the quality of rods and bars and the rate of yield.
This topic originates from the participation Baoshan Steel CorporationΦ8-32mm two roller rods and bars straightening machine project, because the theory predicted value of the straightening strength is small, but the design and the computation of the biggest straightening strength have the important influence to the tube rods and bars' straightening diameter scope. The straightening scope in the thick rods and bars straightening effect is not very ideal in actual straightening, even presents the phenomenon that the holding-down was went against. This article according to the situation of rectifying as well as three curvature mechanical model, proposed mechanical model suits curvature inflection roller shape in this straightening machine, and computations biggest straightening strength of this mechanical model. Through three dimensional modelling of the straightening machine by solidworks and simulation by the finite element analysis software ANSYS and dynamics analysis software ANSYS/LS-DY NA, the article obtains a value of reliable biggest straightening strength, and has carried on a series of analyses of the rigidity and intensity about the straightening machine.
This article obtains the biggest straightening strength through the simulation, the straightening strength small question which in the solution actual straightening meets. Through to the pre-stressed rack just the strength analysis and the ANSYS static state stress analysis, obtained the stress displacement to distribute the rule, reduced the stand stretch to the roller seam influence, enhanced the straightening precision stability.
引文
1.崔甫.矫直原理与矫直机械(第一版)[M],北京：冶金工业出版社,2002.
2.黄华清.轧钢机械[M],北京：冶金工业出版社,1980.
3.崔甫.矫直理论与参数计算(第二版)[M],北京：机械工业出版社,1992.
4. W.Guericke,吴风梧.提高矫直质量的先决条件和可能性[J].重型机械.1981,(7)：59-63.
5. David Hard, Theresa J, Michael Detal. Real-time Control of Twist Deformation.Cirp Ann, 1987,36:77-180.
6. Juen A R. Straightening of circular saw blades. Strips Sheet Tubes,1985, (2):18-20
7.崔甫,施东成。矫直机压弯量计算法的探讨[J].冶金设备.1999,(1)：1-6.
8.崔甫.钢材的矫直与矫直力.东北工学院机械译述。1957.3.
9.王传友.圆材反弯矫直辊形的理论研究[J].重型机械.1980.
10.崔甫.我国首创的复合转毂式矫直机[J].世界金属导报.1991.5(26).
11.曹自立.电子计算机控制的2800十七辊变断面矫直机研制成.重型机械.1983,(2).
12.胡高举,郑才刚,王勤.斜辊矫直机辊型曲线的一种新算法[J],钢铁技术。2002,(6)：29-34.
13.贺镇,胡高举,郑才刚.二辊对辊式管棒材矫直机辊形设计[J].机械02001,(6)：58-59.
14.周高峰,曹巨江.管材矫直机矫直辊曲面数学模型的研究[J].陕西科技大学学报.2005,23(3)：93-96.
15.敖列伟,吴伯杰,王志诚.二辊矫直原理及精度分析[J].重型机械,1997,(16)：41-46.
16.张培庆.高精度管材矫直原理及应用[J].钢管.2002,31(2)：28-30.
17.李强.矫直状态下钢管弹塑性变形区的研究[J].钢管,1995,(4)：34-37.
18.崔甫.钢管矫直中的几个理论问题[J],东北工学院学报,1983,36(3)：77-85.
19.崔甫.矫直技术与理论的新探索[M],北京：冶金工业出版社,2010.
20.黄建国,吕昌.无缝钢管矫直分析[J].包钢科技.2007,33(2)：20-21.
21.李学通,杜风山,于凤琴.中厚板矫直过程的有限元研究[J].重型机械.2005,(1)：44-36.
22. S.H.Jeong, S.H.Lee, GH.Kim, H.J.Seo, T.H.Kim. Computer simulation of U-channel for under-rail rollforming using rigid-plastic finitedement methods. journal of materials processing technology 201(2008)118-122.
23. C.Betegon Biempica, J.J.del Coz Diaz, P.J.Garcia Nieto, I.Penuelas Sanchez. Nonlinear analysis of residual stresses in a rail manufacturing process by FEM. Applied Mathematical Modelling(2007).
24. S.L.Srimani, A.C.Pankaj, J.Basu. Analysis of end straightness of rail durin manufacturing. International Journal of Mechanical Sciences 47(2005)1874-1884
25. Mehmet Firat, Bilgin Kafianoglu, Orhan Eser. Sheet metal forming analyses with alemphasis on the springback deformation. journal of materials processing technology 1 96 (2008)135-148
26. Hoon Huh, Jin Hyuck Heo, Hyoung Wook Lee. Optimization of a roller levelling proces for A17001 T9 pipes with finite dement analysis and Taguchi method. International Journal of Machine Tools & Manufa. cture 43(2003)345-350
27.周存龙,徐静,王国栋,刘相华.中厚板在矫直后的残余应力分布分析[J].重型机械.2005,(2)：21-24
28.刘志亮.棒材二辊矫直机辊型及变形机理研究[D].燕山大学.2008
29. Kee-cheol PARK and Sang-Moo HWANG Development of a Finite Element AnalysiProgram for Roller Leveling and Application for Removing Blanking Bow Defects of ThiSteel Sheet. ISIJ International.2002:9:990.999
30. S.K.Panthi, N.Ramakrishnan, K.K.Pathak, J.S.Chouhan. An analysis of springback isheet metalbending using finite element method(FEM). Journal of Materials Processin Technology 186(2007)120-124.
31. E.Doege, R.Menz, S.Huinink. Analysis of the levelling process based upon an analyti forming model. CIRP Annals—Manufacturing Technology,Volume 51, Issue 1,2002, Page 191.194
32.杨明,张冰,王子才.建模与仿真技术发展趋势分析[J],系统仿真学报,2004,16(9)：1901-1904
33. KORTUM W,et al.The 4th IAVSD-herbertov workshop:"modeling and simulation of mechatronic vehicles:tools, standards and industry demand"-objectives,issues and summary of results[J]. Vehicle System Dynamics Supplement,1999, (33):191-201
34.孙良臣.宝钢离心式飞剪机运动仿真及工艺参数研究[D],东北大学,2009.
35.卫永霞.浅谈仿真技术[J].山西师大体育学院学报研究生论文专刊,2006,21(6)：163-164.
36.李伯虎,柴旭东,朱文海等.现代建模与仿真技术发展中的几个焦点[J],系统仿真学报,2004,16(9)：1871-1878
37.王子才.仿真技术发展及应用[J],中国工程科学.2003,5(2)：40-44.
38.尚晓江,苏建宇,王化锋.ANSYS/LS-DYNA动力分析方法与工程实例(第二版)[M],中国水利水电出版社.2008.
39.白金泽. LS-DYNA3D理论基础与实例分析[M],北京：科学出版社,2005.
40.刘念.辊式矫直机矫直过程有限元仿真[D],武汉科技大学,2008.
41.颜云辉,谢里阳,韩清凯.结构分析中的有限单元法及其应用[M],沈阳：东北大学出版社,2000.
42.王勖成.有限单元法[M].北京：清华大学出版社,2003.
43.赵汝嘉.机械结构有限元分析[M].西安：西安交通大学出版社,1990.
44.姜晋庆.结构弹塑性有限元分析法[M].北京：科学出版社,2002.
45.傅永华.有限元分析基础[M].武汉：武汉大学出版社,2003.
46.郭华.有限元在冶金设备中的应用[J].冶金信息导刊.2002,(3).
47.王纪中.有限元软件及其在冶金设备中的应用[J].冶金设备.2002,(6)：37-39.
48.张翔.优化设计方法与编程[M].北京：中国农业大学出版社,2003.
49.胡国良,任继文。ANSYS11.0有限元分析入门与提高[M].北京：国防工业出版社.2009,1-27.
50.刘鸿文.材料力学(第三版)[M],北京：高等教育出版社,1992.
51.熊杰.钢管矫直变形过程研究与弹塑性有限元分析[D].上海交通大学.2002.
52.熬列伟,熊西.二辊矫直辊面接触应力的计算[J].重型机械,2000,(1)：34-35.
53.周江豹,董为民,张建勇.基于ANSYS/LS-DYNA铜始极片矫直过程动态仿真分析[J].矿冶,2008,17(3)：88-91.
54.闫晓强,宋长江.基于Marc的角钢矫直过程有限元仿真研究[J].冶金设备,2009,(3)：50-56.
55.熊光楞,王克明.二十一世纪仿真技术的发展及其对制造业的影响[J].全球化制造高级论坛暨21世纪仿真技术研讨会论文集.13-18
56.高燕.H型钢辊式矫直中断面畸变的研究[D].北京科技大学.2006.
57.李培燕,张旭.预应力矫直机机架分析[J].科技情报开发与经济.2009,19(32)：214-215
2.黄华清.轧钢机械[M],北京：冶金工业出版社,1980.
3.崔甫.矫直理论与参数计算(第二版)[M],北京：机械工业出版社,1992.
4. W.Guericke,吴风梧.提高矫直质量的先决条件和可能性[J].重型机械.1981,(7)：59-63.
5. David Hard, Theresa J, Michael Detal. Real-time Control of Twist Deformation.Cirp Ann, 1987,36:77-180.
6. Juen A R. Straightening of circular saw blades. Strips Sheet Tubes,1985, (2):18-20
7.崔甫,施东成。矫直机压弯量计算法的探讨[J].冶金设备.1999,(1)：1-6.
8.崔甫.钢材的矫直与矫直力.东北工学院机械译述。1957.3.
9.王传友.圆材反弯矫直辊形的理论研究[J].重型机械.1980.
10.崔甫.我国首创的复合转毂式矫直机[J].世界金属导报.1991.5(26).
11.曹自立.电子计算机控制的2800十七辊变断面矫直机研制成.重型机械.1983,(2).
12.胡高举,郑才刚,王勤.斜辊矫直机辊型曲线的一种新算法[J],钢铁技术。2002,(6)：29-34.
13.贺镇,胡高举,郑才刚.二辊对辊式管棒材矫直机辊形设计[J].机械02001,(6)：58-59.
14.周高峰,曹巨江.管材矫直机矫直辊曲面数学模型的研究[J].陕西科技大学学报.2005,23(3)：93-96.
15.敖列伟,吴伯杰,王志诚.二辊矫直原理及精度分析[J].重型机械,1997,(16)：41-46.
16.张培庆.高精度管材矫直原理及应用[J].钢管.2002,31(2)：28-30.
17.李强.矫直状态下钢管弹塑性变形区的研究[J].钢管,1995,(4)：34-37.
18.崔甫.钢管矫直中的几个理论问题[J],东北工学院学报,1983,36(3)：77-85.
19.崔甫.矫直技术与理论的新探索[M],北京：冶金工业出版社,2010.
20.黄建国,吕昌.无缝钢管矫直分析[J].包钢科技.2007,33(2)：20-21.
21.李学通,杜风山,于凤琴.中厚板矫直过程的有限元研究[J].重型机械.2005,(1)：44-36.
22. S.H.Jeong, S.H.Lee, GH.Kim, H.J.Seo, T.H.Kim. Computer simulation of U-channel for under-rail rollforming using rigid-plastic finitedement methods. journal of materials processing technology 201(2008)118-122.
23. C.Betegon Biempica, J.J.del Coz Diaz, P.J.Garcia Nieto, I.Penuelas Sanchez. Nonlinear analysis of residual stresses in a rail manufacturing process by FEM. Applied Mathematical Modelling(2007).
24. S.L.Srimani, A.C.Pankaj, J.Basu. Analysis of end straightness of rail durin manufacturing. International Journal of Mechanical Sciences 47(2005)1874-1884
25. Mehmet Firat, Bilgin Kafianoglu, Orhan Eser. Sheet metal forming analyses with alemphasis on the springback deformation. journal of materials processing technology 1 96 (2008)135-148
26. Hoon Huh, Jin Hyuck Heo, Hyoung Wook Lee. Optimization of a roller levelling proces for A17001 T9 pipes with finite dement analysis and Taguchi method. International Journal of Machine Tools & Manufa. cture 43(2003)345-350
27.周存龙,徐静,王国栋,刘相华.中厚板在矫直后的残余应力分布分析[J].重型机械.2005,(2)：21-24
28.刘志亮.棒材二辊矫直机辊型及变形机理研究[D].燕山大学.2008
29. Kee-cheol PARK and Sang-Moo HWANG Development of a Finite Element AnalysiProgram for Roller Leveling and Application for Removing Blanking Bow Defects of ThiSteel Sheet. ISIJ International.2002:9:990.999
30. S.K.Panthi, N.Ramakrishnan, K.K.Pathak, J.S.Chouhan. An analysis of springback isheet metalbending using finite element method(FEM). Journal of Materials Processin Technology 186(2007)120-124.
31. E.Doege, R.Menz, S.Huinink. Analysis of the levelling process based upon an analyti forming model. CIRP Annals—Manufacturing Technology,Volume 51, Issue 1,2002, Page 191.194
32.杨明,张冰,王子才.建模与仿真技术发展趋势分析[J],系统仿真学报,2004,16(9)：1901-1904
33. KORTUM W,et al.The 4th IAVSD-herbertov workshop:"modeling and simulation of mechatronic vehicles:tools, standards and industry demand"-objectives,issues and summary of results[J]. Vehicle System Dynamics Supplement,1999, (33):191-201
34.孙良臣.宝钢离心式飞剪机运动仿真及工艺参数研究[D],东北大学,2009.
35.卫永霞.浅谈仿真技术[J].山西师大体育学院学报研究生论文专刊,2006,21(6)：163-164.
36.李伯虎,柴旭东,朱文海等.现代建模与仿真技术发展中的几个焦点[J],系统仿真学报,2004,16(9)：1871-1878
37.王子才.仿真技术发展及应用[J],中国工程科学.2003,5(2)：40-44.
38.尚晓江,苏建宇,王化锋.ANSYS/LS-DYNA动力分析方法与工程实例(第二版)[M],中国水利水电出版社.2008.
39.白金泽. LS-DYNA3D理论基础与实例分析[M],北京：科学出版社,2005.
40.刘念.辊式矫直机矫直过程有限元仿真[D],武汉科技大学,2008.
41.颜云辉,谢里阳,韩清凯.结构分析中的有限单元法及其应用[M],沈阳：东北大学出版社,2000.
42.王勖成.有限单元法[M].北京：清华大学出版社,2003.
43.赵汝嘉.机械结构有限元分析[M].西安：西安交通大学出版社,1990.
44.姜晋庆.结构弹塑性有限元分析法[M].北京：科学出版社,2002.
45.傅永华.有限元分析基础[M].武汉：武汉大学出版社,2003.
46.郭华.有限元在冶金设备中的应用[J].冶金信息导刊.2002,(3).
47.王纪中.有限元软件及其在冶金设备中的应用[J].冶金设备.2002,(6)：37-39.
48.张翔.优化设计方法与编程[M].北京：中国农业大学出版社,2003.
49.胡国良,任继文。ANSYS11.0有限元分析入门与提高[M].北京：国防工业出版社.2009,1-27.
50.刘鸿文.材料力学(第三版)[M],北京：高等教育出版社,1992.
51.熊杰.钢管矫直变形过程研究与弹塑性有限元分析[D].上海交通大学.2002.
52.熬列伟,熊西.二辊矫直辊面接触应力的计算[J].重型机械,2000,(1)：34-35.
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