圆盘剪剪切过程的有限元模拟和实验研究
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摘要
我国钢铁产量已经连续多年位居世界第一,钢铁企业是国民经济的主要支柱,它的发展状况很大程度上反映了一个国家的实力。现代钢铁行业发展的一个着眼点就是提高钢材的质量。精整工序是保证冷轧产品质量的关键环节,高精度切边圆盘剪是板带精整作业线上的核心设备之一,其精度的高低直接影响着板带材的切边质量。
本课题以中国重型机械研究院项目为依托,对切边圆盘剪的关键技术进行了研究。通过对切边圆盘剪的工作原理和剪切机理的研究,用有限元分析软件ANSYS/LS-DYNA建立了切边圆盘剪剪切钢板的有限元模型,并采用显式动力学有限元算法对剪切过程进行了模拟分析。分析了钢板剪切断裂的过程,得到了钢板的应力-应变变化,废边的运动规律,断裂区单元的应力变化,剪切后钢板宽度方向的塑性应变分布和剪切过程中的剪切力变化规律。并分析了重叠量、侧向间隙、剪切速度等工艺参数对剪切力的影响。设计了切边圆盘剪剪切力测试装置,并对剪切力进行现场测试。有限元模拟得到的剪切力与实测值和经验公式计算值差距很小,证实了有限元模拟结果的正确性。
采用计算机仿真和实验相结合的方法来研究板带剪切过程,可以缩短剪切机的开发周期,降低生产成本。同时,本文采用的研究方法为剪切理论的进一步发展提供了新的研究手段。
Our country's steel output has ranked first in the world for many years, iron and steel enterprises are the main pillars of the national economy, its development largely reflects the strength of a country. The development of a modern iron and steel industry is to increase the focus of the quality of steel. Cold finishing process is the key to ensure the product quality, the precision cutting edge trimmer is one of the core equipment of a strip finishing line, its direct impact on the level of precision sheet and strip trimming quality.
This subject takes China National Heavy Machinery Research Institute project as a backing, has conducted the research to key technologies of the cutting edge trimmer. As the study of cutting edge trimmer on the mechanism and shear principle, the cutting-edge steel plate shear finite element model has established by the finite element analysis software ANSYS / LS-DYNA, and using explicit dynamic finite element algorithm to simulate the process of shearing. The steel plate shear fracture process is analyzed, a plate of stress– strain is received, the movement rule of waste side, element stress change of fracture zone, the plastic strain distribution of sheared plate width direction and the change of shear force in the shearing process. And the impact of the parameters on shear force was analyzed, which includes overlap, side gap, cutting speeds and so on. A cutting-edge disc shear force testing equipment was designed, and shear force was tested. The gap of shear force among finite element simulation, the tested value and calculated value, the results confirmed the correctness of finite element simulation.
Using computer simulation and experimental methods to study the strip shearing process, can reduce shearing machine development cycle, reduce production costs. Meanwhile, the research methods used in this paper provides a new means of research for the further development of shear theory.
本课题以中国重型机械研究院项目为依托,对切边圆盘剪的关键技术进行了研究。通过对切边圆盘剪的工作原理和剪切机理的研究,用有限元分析软件ANSYS/LS-DYNA建立了切边圆盘剪剪切钢板的有限元模型,并采用显式动力学有限元算法对剪切过程进行了模拟分析。分析了钢板剪切断裂的过程,得到了钢板的应力-应变变化,废边的运动规律,断裂区单元的应力变化,剪切后钢板宽度方向的塑性应变分布和剪切过程中的剪切力变化规律。并分析了重叠量、侧向间隙、剪切速度等工艺参数对剪切力的影响。设计了切边圆盘剪剪切力测试装置,并对剪切力进行现场测试。有限元模拟得到的剪切力与实测值和经验公式计算值差距很小,证实了有限元模拟结果的正确性。
采用计算机仿真和实验相结合的方法来研究板带剪切过程,可以缩短剪切机的开发周期,降低生产成本。同时,本文采用的研究方法为剪切理论的进一步发展提供了新的研究手段。
Our country's steel output has ranked first in the world for many years, iron and steel enterprises are the main pillars of the national economy, its development largely reflects the strength of a country. The development of a modern iron and steel industry is to increase the focus of the quality of steel. Cold finishing process is the key to ensure the product quality, the precision cutting edge trimmer is one of the core equipment of a strip finishing line, its direct impact on the level of precision sheet and strip trimming quality.
This subject takes China National Heavy Machinery Research Institute project as a backing, has conducted the research to key technologies of the cutting edge trimmer. As the study of cutting edge trimmer on the mechanism and shear principle, the cutting-edge steel plate shear finite element model has established by the finite element analysis software ANSYS / LS-DYNA, and using explicit dynamic finite element algorithm to simulate the process of shearing. The steel plate shear fracture process is analyzed, a plate of stress– strain is received, the movement rule of waste side, element stress change of fracture zone, the plastic strain distribution of sheared plate width direction and the change of shear force in the shearing process. And the impact of the parameters on shear force was analyzed, which includes overlap, side gap, cutting speeds and so on. A cutting-edge disc shear force testing equipment was designed, and shear force was tested. The gap of shear force among finite element simulation, the tested value and calculated value, the results confirmed the correctness of finite element simulation.
Using computer simulation and experimental methods to study the strip shearing process, can reduce shearing machine development cycle, reduce production costs. Meanwhile, the research methods used in this paper provides a new means of research for the further development of shear theory.
引文
[1]钢铁产业调整和振兴规划. http://www.gov.cn/zwgk/2009-03/20/content_1264318.htm
[2]苏亚红.我国冷轧板带生产状况及展望[J].冶金信息导刊,2007,5:44-48.
[3]景群平,张勇安,王社昌,许展望.冷轧板带材切边圆盘剪重叠量调整方法探讨[J].重型机械,2008,1:35-39.
[4]刘宝衍主编.轧钢机械设备[M].北京:冶金工业出版社,1986:135-137.
[5]王若然,刘兰馨.3500mm圆盘剪和碎边剪在精整区的工艺布置[J].金属世界,2009年增刊:61-62.
[6]冶金工业部有色金属加工设计研究院主编.板带车间机械设备设计(下册)[M].北京:冶金工业出版社,1983:172-191.
[7]V.P.Sankevich.Rotary Disk Shears with Mechanized Trimming Adjustment[J].Metallurgist,2007,14(3):186-187.
[8]邵峰跃,张国彪,王志斌,周大勇.带材纵横剪机列的国内外发展动向[C].中国铜铝加工装备研讨会文集.2004:171-173.
[9]杨秀梅.变宽度圆盘剪切机虚拟样机研究[D].北京:北方工业大学,2008.
[10]彭建东.AWC型圆盘剪的国产化[J].江苏冶金,2008,36(2):22-25.
[11]隋涛. 1250圆盘剪结构分析与参数选择[J].安徽冶金科技职业学院学报,2005,15(1):12-14.
[12]周国盈.带钢精整设备[M].北京:机械工业出版社,1982:73-83.
[13]施东成.轧钢机械设计方法[M].北京:冶金工业出版社,1991:381-390.
[14]李龙海,李瑞雪.圆盘剪纵剪机力能参数的计算及测定[J].冶金设备,1995,90(2):10-12.
[15]刘培锷,吴国彦.圆盘剪切机剪切力和轴向力的实验研究[J].重型机械,1994,5:22-26.
[16]Marcal P V,King I P. Elastic-plastic Analysis of Twodimensional Systems by the Finite Element Method [J]. Int.J.Mech.Sci.1967,(9):143-145.
[17]赵静,束学道,胡正寰.工艺参数对多楔轧件接口质量的影响规律[J].机械工程学报,2008,44(11):209-214.
[18]卢建霞.平行刃剪切机剪切过程的仿真模拟及机架的有限元分析[D].鞍山:鞍山钢铁学院,2002.
[19]常军然,付群峰.圆盘剪剪切力计算与计算机仿真研究[J].机械工程师,2008,8:81-82.
[20]张杰.精冲断裂裂纹扩展有限元算法研究[D].上海:上海交通大学,2007.
[21]房树锋.曲柄式飞剪设计及其剪切过程的有限元模拟[D].上海:上海交通大学,2007.
[22]马立峰.空间剪切机构钢板滚切剪技术的研究及应用[D].太原:太原理工大学,2008.
[23]陶有能.切边圆盘剪设计[J].华中科技大学学报,2006,23(2):77-79.
[24]罗传越.无动力双塔回转式圆盘剪切机的研究与开发[D].重庆:重庆大学,2007.
[25]S.M.Nosenko.Operation of the plate rotary shears[J].Metallurgist,1965,9(4):213-215.
[26]杨蔓丽.阶梯形刃口精密冲裁过程有限元模拟及实验研究[D].秦皇岛:燕山大学,2007.
[27]黄庆学主编.轧钢机械设计[M].北京:冶金工业出版社,2007:221-279.
[28]赵振铎,高军,邵明志,张召铎.实用冲裁技术[M].北京:化学工业出版社,2004:42-67.
[29]徐秉业,刘信声.应用弹塑性力学[M].北京:清华大学出版社,1995:73-83.
[30]李同林.应用弹塑性力学[M].武汉:中国地质大学出版社,2002:48-52.
[31]曾攀.有限元分析及应用[M].北京:清华大学出版社,2004:318-342.
[32]杨桂通.弹塑性力学引论[M].北京:清华大学出版社,2004:43-77.
[33]王勖成.有限单元法[M].北京:清华大学出版社,2003:545-599.
[34]Gurson AL.Continuum theory of ductile rupture by void nucleation and growth:Part 1 Yield criteria and flow rules for porous ductile media[J].J.Engng Mater.Tech,1977,99(2):2~15.
[35]赵晓雯.管材滚压剪切过程的数值模拟及实验研究[D].秦皇岛:燕山大学,2003.
[36]J.Breitling,V.Chernauskas,E.Taupin,T.Altan.Precision shear of billets-special equipment and process simulation[J].J.Mater.Process.Techno,71(1997):119-125.
[37]ANSYS/LS-DYNA使用指南[M].ANSYS软件公司,2000.
[38]王富耻. ANSYS10.0有限元分析理论与工程应用[M].北京:电子工业出版社,2006:311-312.
[39]李春胜,黄德彬主编.机械工程材料手册(上册)[M].北京:电子工业出版社,2006.
[40]何涛等. ANSYS10.0/LS-DYNA非线性有限元分析实例指导教程[M].北京:机械工业出版社,2007.
[41]John O.Hallquist,LS-DYNA THEORETICAL MANUAL,Livermore Software Technology Corporation,1998. [ 42 ] LS-DYNA KEYWORD USER’S MANUAL VOLUME1.Livermore Software Technology Corporation,2007.
[43]Chen Zhi-jian,Yuan Jian-honh,Zhao Yao.Impact Experiment Study of Ship Building Steel at 450MPa Level and Constitutive Model of Cowper-Symonds[J].Journal of Ship Mechanics,2007,11(6):933-941.
[44]孙大刚,宋勇,林慕义,张学良.黏弹性悬架阻尼缓冲件动态接触有限元模拟研究[J].农业工程学报,2008,24(1):24-28.
[45]赵海鸥.LS-DYNA动力分析指南[M].北京:兵器工业出版社,2003:14-26.
[46]王仕杰.大直径ERW直缝焊管排辊成型工艺研究[D].太原:太原科技大学,2007.
[2]苏亚红.我国冷轧板带生产状况及展望[J].冶金信息导刊,2007,5:44-48.
[3]景群平,张勇安,王社昌,许展望.冷轧板带材切边圆盘剪重叠量调整方法探讨[J].重型机械,2008,1:35-39.
[4]刘宝衍主编.轧钢机械设备[M].北京:冶金工业出版社,1986:135-137.
[5]王若然,刘兰馨.3500mm圆盘剪和碎边剪在精整区的工艺布置[J].金属世界,2009年增刊:61-62.
[6]冶金工业部有色金属加工设计研究院主编.板带车间机械设备设计(下册)[M].北京:冶金工业出版社,1983:172-191.
[7]V.P.Sankevich.Rotary Disk Shears with Mechanized Trimming Adjustment[J].Metallurgist,2007,14(3):186-187.
[8]邵峰跃,张国彪,王志斌,周大勇.带材纵横剪机列的国内外发展动向[C].中国铜铝加工装备研讨会文集.2004:171-173.
[9]杨秀梅.变宽度圆盘剪切机虚拟样机研究[D].北京:北方工业大学,2008.
[10]彭建东.AWC型圆盘剪的国产化[J].江苏冶金,2008,36(2):22-25.
[11]隋涛. 1250圆盘剪结构分析与参数选择[J].安徽冶金科技职业学院学报,2005,15(1):12-14.
[12]周国盈.带钢精整设备[M].北京:机械工业出版社,1982:73-83.
[13]施东成.轧钢机械设计方法[M].北京:冶金工业出版社,1991:381-390.
[14]李龙海,李瑞雪.圆盘剪纵剪机力能参数的计算及测定[J].冶金设备,1995,90(2):10-12.
[15]刘培锷,吴国彦.圆盘剪切机剪切力和轴向力的实验研究[J].重型机械,1994,5:22-26.
[16]Marcal P V,King I P. Elastic-plastic Analysis of Twodimensional Systems by the Finite Element Method [J]. Int.J.Mech.Sci.1967,(9):143-145.
[17]赵静,束学道,胡正寰.工艺参数对多楔轧件接口质量的影响规律[J].机械工程学报,2008,44(11):209-214.
[18]卢建霞.平行刃剪切机剪切过程的仿真模拟及机架的有限元分析[D].鞍山:鞍山钢铁学院,2002.
[19]常军然,付群峰.圆盘剪剪切力计算与计算机仿真研究[J].机械工程师,2008,8:81-82.
[20]张杰.精冲断裂裂纹扩展有限元算法研究[D].上海:上海交通大学,2007.
[21]房树锋.曲柄式飞剪设计及其剪切过程的有限元模拟[D].上海:上海交通大学,2007.
[22]马立峰.空间剪切机构钢板滚切剪技术的研究及应用[D].太原:太原理工大学,2008.
[23]陶有能.切边圆盘剪设计[J].华中科技大学学报,2006,23(2):77-79.
[24]罗传越.无动力双塔回转式圆盘剪切机的研究与开发[D].重庆:重庆大学,2007.
[25]S.M.Nosenko.Operation of the plate rotary shears[J].Metallurgist,1965,9(4):213-215.
[26]杨蔓丽.阶梯形刃口精密冲裁过程有限元模拟及实验研究[D].秦皇岛:燕山大学,2007.
[27]黄庆学主编.轧钢机械设计[M].北京:冶金工业出版社,2007:221-279.
[28]赵振铎,高军,邵明志,张召铎.实用冲裁技术[M].北京:化学工业出版社,2004:42-67.
[29]徐秉业,刘信声.应用弹塑性力学[M].北京:清华大学出版社,1995:73-83.
[30]李同林.应用弹塑性力学[M].武汉:中国地质大学出版社,2002:48-52.
[31]曾攀.有限元分析及应用[M].北京:清华大学出版社,2004:318-342.
[32]杨桂通.弹塑性力学引论[M].北京:清华大学出版社,2004:43-77.
[33]王勖成.有限单元法[M].北京:清华大学出版社,2003:545-599.
[34]Gurson AL.Continuum theory of ductile rupture by void nucleation and growth:Part 1 Yield criteria and flow rules for porous ductile media[J].J.Engng Mater.Tech,1977,99(2):2~15.
[35]赵晓雯.管材滚压剪切过程的数值模拟及实验研究[D].秦皇岛:燕山大学,2003.
[36]J.Breitling,V.Chernauskas,E.Taupin,T.Altan.Precision shear of billets-special equipment and process simulation[J].J.Mater.Process.Techno,71(1997):119-125.
[37]ANSYS/LS-DYNA使用指南[M].ANSYS软件公司,2000.
[38]王富耻. ANSYS10.0有限元分析理论与工程应用[M].北京:电子工业出版社,2006:311-312.
[39]李春胜,黄德彬主编.机械工程材料手册(上册)[M].北京:电子工业出版社,2006.
[40]何涛等. ANSYS10.0/LS-DYNA非线性有限元分析实例指导教程[M].北京:机械工业出版社,2007.
[41]John O.Hallquist,LS-DYNA THEORETICAL MANUAL,Livermore Software Technology Corporation,1998. [ 42 ] LS-DYNA KEYWORD USER’S MANUAL VOLUME1.Livermore Software Technology Corporation,2007.
[43]Chen Zhi-jian,Yuan Jian-honh,Zhao Yao.Impact Experiment Study of Ship Building Steel at 450MPa Level and Constitutive Model of Cowper-Symonds[J].Journal of Ship Mechanics,2007,11(6):933-941.
[44]孙大刚,宋勇,林慕义,张学良.黏弹性悬架阻尼缓冲件动态接触有限元模拟研究[J].农业工程学报,2008,24(1):24-28.
[45]赵海鸥.LS-DYNA动力分析指南[M].北京:兵器工业出版社,2003:14-26.
[46]王仕杰.大直径ERW直缝焊管排辊成型工艺研究[D].太原:太原科技大学,2007.