中厚板平面形状控制的模拟研究
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摘要
中厚板产品广泛应用于油气输送管线、船舶、桥梁、容器、锅炉、海洋构件、建筑等国民经济的众多领域。在中厚板生产中，提高成材率是节省能源与资源，降低成本的重要手段，成材率的高低直接影响到企业的经济效益。平面形状控制技术是中厚板生产的一项关键技术，可以大幅度提高中厚板成材率，我国目前尚未充分掌握该项技术，有待于积极开发。
本文首先回顾了国内外中厚板生产平面形状控制的研究情况；系统阐述了弹塑性有限元法基本理论；在多次考察秦皇岛中板厂实际生产线的基础上，以提高中厚板成材率为目的，以不同轧制规程下中厚板的平面形状变化为研究对象，采用数值分析和物理实验相结合的方法，对中厚板轧制中平面形状的变化规律进行了研究。
根据展宽比的不同，制定了8种典型的轧制规程，分别采用大型商用有限元软件MARC进行了从板坯到成品的轧制全过程模拟，分析了轧件金属在不同典型道次中的流动行为。通过比较各种轧制规程下的平面形状，得到了成材率最高和生产率及成材率综合较好的轧制规程。最后以铅为材料，在燕山大学轧钢实验室二辊轧机上进行了物理实验研究，验证了数值模拟结果的正确性及准确性。本课题对于中厚板平面形状控制的研究工作在理论上为提高我国中厚板行业的成材率奠定了必要的基础。
The plate products are widely used in many fields such as pipeline of petroleum and natural gas, shipping, bridge, container, boiler, oceanic component, construction and so on. Increasing product yields by reducing crop losses is one of the most prominent ways to save energy consumption and reach cost down purpose, which largely affects the enterprise economic interests. The objective of plan view control is to achieve the final plate pattern as rectangular as possible, thus improving plate yield, by optimizing the rolling schedules. This technology is undeveloped in our country and worthwhile to carry out systemic investigation.
In this study, the research progress of plan view control technology is reviewed and summarized. The fundamental theory of elastoplastic finite element method (FEM) is given. Based on the investigation of the actual production performance of Qinhuangdao Plate Mill Plant, the rolling process mathematic models of eight typical rolling schedules are established, the plan view patterns according to different rolling schedules are analyzed by numerical simulations and experiment tests.
The plate rolling processes, from forming pass to finishing pass, with different rolling schedules are simulated by the famous finite element analysis software, MARC, aimed to investigate the metal deformation behaviors and the plan view pattern changing history during rolling. The best rolling schedule for maximum yield has been obtained after the analysis and comparison of eight typical rolling schedules. On the two high mill in the Rolling Lab of Yanshan University, the numerical results are examined by physical simulations with lead specimen. It shows that they meet each other quite well. The results have provided valuable information on the setup of rolling schedule in the plate production. This study is meaningful for reducing defective edge shape and improving the production yields on both theory and practice.
本文首先回顾了国内外中厚板生产平面形状控制的研究情况；系统阐述了弹塑性有限元法基本理论；在多次考察秦皇岛中板厂实际生产线的基础上，以提高中厚板成材率为目的，以不同轧制规程下中厚板的平面形状变化为研究对象，采用数值分析和物理实验相结合的方法，对中厚板轧制中平面形状的变化规律进行了研究。
根据展宽比的不同，制定了8种典型的轧制规程，分别采用大型商用有限元软件MARC进行了从板坯到成品的轧制全过程模拟，分析了轧件金属在不同典型道次中的流动行为。通过比较各种轧制规程下的平面形状，得到了成材率最高和生产率及成材率综合较好的轧制规程。最后以铅为材料，在燕山大学轧钢实验室二辊轧机上进行了物理实验研究，验证了数值模拟结果的正确性及准确性。本课题对于中厚板平面形状控制的研究工作在理论上为提高我国中厚板行业的成材率奠定了必要的基础。
The plate products are widely used in many fields such as pipeline of petroleum and natural gas, shipping, bridge, container, boiler, oceanic component, construction and so on. Increasing product yields by reducing crop losses is one of the most prominent ways to save energy consumption and reach cost down purpose, which largely affects the enterprise economic interests. The objective of plan view control is to achieve the final plate pattern as rectangular as possible, thus improving plate yield, by optimizing the rolling schedules. This technology is undeveloped in our country and worthwhile to carry out systemic investigation.
In this study, the research progress of plan view control technology is reviewed and summarized. The fundamental theory of elastoplastic finite element method (FEM) is given. Based on the investigation of the actual production performance of Qinhuangdao Plate Mill Plant, the rolling process mathematic models of eight typical rolling schedules are established, the plan view patterns according to different rolling schedules are analyzed by numerical simulations and experiment tests.
The plate rolling processes, from forming pass to finishing pass, with different rolling schedules are simulated by the famous finite element analysis software, MARC, aimed to investigate the metal deformation behaviors and the plan view pattern changing history during rolling. The best rolling schedule for maximum yield has been obtained after the analysis and comparison of eight typical rolling schedules. On the two high mill in the Rolling Lab of Yanshan University, the numerical results are examined by physical simulations with lead specimen. It shows that they meet each other quite well. The results have provided valuable information on the setup of rolling schedule in the plate production. This study is meaningful for reducing defective edge shape and improving the production yields on both theory and practice.
引文
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熊尚武, 姜正义, 刘相华,等.粗轧机组板坯调宽预测模型的实验验证与应用.钢铁, 1999.8(8):41-44
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帅习元, 葛懋琦, 宋耀华,等.中厚板轧制平面形状模糊控制.武钢技术, 2000,5
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贺达伦.现代化宽厚板厂高成材率确保技术.宝钢技术,2000,(1):22-26
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Wada Bompei. Automatic plan view pattern control and automatic gauge control for heavy plate mill. Sumitomo Metals, 1998,6: 79-87
Xiukun Ding. Establishment of Mathematical Models for Plan View Pattern Control of Plate. Iron and Steel,1998: 33-37
Chun M.S. Optimization of the Amount of Edging to Increase Rolling Yields in a Plate Mill. Journal of Materials Processing Technology,2000,8: 11-16
Chun Myung-Sik. Optimization of Edging Amount for High Accuracy Plan View Control in Plate Mill. Steel Research,2001,6: 17-23
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肖军, 李尚健.金属材料弯曲成形计算机模拟进展.塑性工程学报, 1997(6):3-8
左旭, 卫原平等.金属体积成形三维数值仿真的研究进展.力学进展,1999,29(4):49-55
乔端, 钱仁根.非线性有限元法及其在塑性加工中的应用.北京:冶金工业出版社,1990: 12-20
熊尚武, 刘相华, 王国栋等. 热带粗轧机组立轧稳定轧制的变形规律.东北大学学报(自然科学版),1997,(1):72-76
熊尚武, 刘相华, 王国栋,等.热带粗轧机组立轧过程的三维有限元模拟.工程力学, 1997,(2):96-101
熊尚武, 朱祥霖, 李洪斌,等.热带粗轧机组调宽工艺中数学模型的建立.上海金属, 1997,(1):39-43
熊尚武, 朱祥霖, 韩力,等.热带粗轧机组调宽时材料的变形行为.上海金属, 1996.5(1):17-24
熊尚武, 姜正义, 刘相华,等.粗轧机组板坯调宽预测模型的实验验证与应用.钢铁, 1999.8(8):41-44
丁修堃, 于九明, 荆其臻,等.中厚板平面形状变形规律及其测定的研究.轧钢,1998, (2):3-6
于九明, 丁修堃, 李永波.平立辊协调轧制控制厚板平面形状的试验研究.国内冶金, 1999,(3):40-43
丁修堃, 于九明, 张延华,等.中厚板平面形状数学模型的建立.钢铁,1998,2(2):33-37
丁修堃, 马博, 王贞祥.中厚板平面形状控制中的GM-AGC系统.东北大学学报(自然科学版),1998,2(1):8-10
张殿华, 王君, 李建平,等.中厚板平面形状计算机控制系统.钢铁,2000,5(5):40-43
熊尚武, 吕程, 刘相华,等.“狗骨”材平轧的三维刚塑性有限元分析.钢铁研究学报, 2000(2):14-17
魏立群, 刘谋洲, 张杏耀,等.扁锭轧制中厚板过程平面形状控制的实验研究.上海金属, 1999,(2):34-37
程晓茹, 胡衍生, 宋耀华,等.中厚板平面形状控制的立轧参数神经网络识别.武汉科技大学学报(自然科学版),2000,9(3):236-239
帅习元, 葛懋琦, 宋耀华,等.中厚板轧制平面形状模糊控制.武钢技术, 2000,5
(3):9-41
张军, 田锡亮.轧长展宽法控制边部形状的研究.武汉钢铁学院学报,1994,(12):368-374
张国儒, 李青, 黄福珪,等.中板展宽纵轧工艺研究.钢铁,1994,11(11):26-29
金自力, 黎景全.改进钢锭断面形状提高厚板成材率的变形实验.钢铁研究学报, 1997,(5):11-16
刘相华, 王国栋.热轧带钢新技术的发展.钢铁研究,2000,(5):1-24
张燕燕, 曹建宁.厚板生产技术的发展.轧钢,2001,(2):35-38
朱敏之.国外厚板生产工艺技术的进步.宽厚板,2000,(3):39-42
李春福, 孟祥利.利用平面板形控制提高厚板的成材率.鞍山钢铁学院学报, 1998(6):17-19
贺达伦.现代化宽厚板厂高成材率确保技术.宝钢技术,2000,(1):22-26
Tsubota Kazuya. Development of The New Plan View Pattern Control System in Plate Rolling. Proceedings of the Mineral Waste Utilization Symposium,1980,10: 193-204
Yanazawa Tadaaki. Development of a New Plan View Pattern Control System in Plate Rolling. Kawasaki Steel Technical Report, 1980,9:33-46
Watanabe Hideki. Development of New Plan View Pattern Control System in Plate Rolling. Tetsu-To-Hagane/Journal of the Iron and Steel Institute of Japan, 1981,10: 2412-2418
Moon Young-Hoon. Physical Modelling of Edge Rolling in Plate Mill with Plasticine. Steel Research,1993,11: 557-563
Wada Bompei. Automatic plan view pattern control and automatic gauge control for heavy plate mill. Sumitomo Metals, 1998,6: 79-87
Xiukun Ding. Establishment of Mathematical Models for Plan View Pattern Control of Plate. Iron and Steel,1998: 33-37
Chun M.S. Optimization of the Amount of Edging to Increase Rolling Yields in a Plate Mill. Journal of Materials Processing Technology,2000,8: 11-16
Chun Myung-Sik. Optimization of Edging Amount for High Accuracy Plan View Control in Plate Mill. Steel Research,2001,6: 17-23
和田凡平, 古川裕之.厚板压延にぉけゐ平面形状.板厚制御技术[J],住友金属, 1998,50(1):81
有贺勇,上村尚志,吉里勉.厚板TFP技术[J].川崎制铁技报,1996,28(3):62
Okamura Isamu. Control System of TFP Edger in Plate Rolling-Development Of a Process for .Manufacturing TFP(Trimming Free Plate)-II,1986,10: 21-1583
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