十五辊组合矫直机关键技术及理论模型的研究
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摘要
中厚板生产线上的矫直机作为保证中厚板质量的重要设备,直接决定着产品的生产率、平直度精度、应力消除程度以及交货质量的高低。随产量和质量要求的逐年提高,中厚板品种规格趋于多样化,特别是1975年以后控轧控冷(TMCP)等技术的广泛应用,板材的矫直温度降低、材料的屈服强度提高等多种因素,对矫直设备在强度、刚度、功能和自动化程度等方面提出了更高的要求。但由于矫直理论、工艺模型等核心技术积累不够,国产中厚板辊式矫直机与国外同类型设备相比,矫直效率、不平度精度、自动化程度均有一定差距。
本文以某钢铁公司不锈钢热处理线3000mm十五辊组合矫直机的开发设计项目和其他热处理矫直机、冷矫直机开发设计项目为依托,对中厚板矫直理论及计算模型、组合矫直机关键技术和其它第三代矫直机关键技术进行研究,得出以下结论：
1、十五辊矫直机为高强度板设计,其核心技术是在高强薄板矫直时,采用平行矫直方案和辊系间张力技术,提高矫直精度,扩大矫直板材的材料强度范围。通过对矫直方案影响因素研究表明,在组合矫直机中实施平行矫直方案是可行性的；并且通过建立组合矫直大小辊系参数优化目标、优化约束条件,采用数值计算方法得出了组合矫直机可取辊系参数系列。
2、组合矫直机薄规格板材穿带问题为矫直过程中板材咬入问题。通过几何解析分析,提出了矫直过程中板材穿带咬入的基本条件,并推导咬入参数接触角α。与组合矫直机中间过渡辊辊系参数相关三个咬入参数接触角决定了组合矫直机薄板穿带运行稳定性。通过分析建立中间过渡辊相关辊系参数优化的数学模型,采用复合单纯形法对其进行求解,保证了组合矫直机穿带稳定。
3、建立截面分层的矫直内弯矩算法,得到矫直过程中截面上各种应力＼应变。并通过上述矫直计算模型,进一步提出了不充分变形矫直工艺、十五辊组合矫直机工艺方案。研究表明,不充分变形矫直工艺不同于现有矫直工艺，适用于厚板矫直过程。采用不充分变形多道次矫直工艺方案,扩大了矫直范围,可矫轧件变形抗力极限提高了1／4～1／3。组合矫直机辊系有别于普通矫直机辊系,在这种组合辊系和平行矫直方案的矫直过程明显不同于等辊距辊系倾斜的矫直方案。当采用平行矫直方案,相同的压下量在不同的辊系中使板材的弯曲程度不同。组合矫直前面的小辊系使轧件得到大的弯曲曲率相同弯曲变形,使残余曲率的范围快速减小。组合矫直后面的大辊系使轧件得到小的弯曲曲率相同弯曲变形,逐步减小残余曲率的数值。
4、由于矫直辊的作用,矫直单元对浪型压缩变形产生的拉伸区和压缩区,拉伸区和压缩区的应力／应变叠加弯曲变形后,产生应力中性层、应变中性层偏移。中性层的偏移和残余应变使不同部位的纵向纤维产生拉伸和压缩,是浪型矫直的根本原因。模拟结果表明：由于浪形存在矫直后,板材存在较大的残余应力,同时有横向浪形比无浪形的矫直力能参数增加。
5、通过对自学习的变形抗力模型在矫直模型中的应用研究。研究表明：模型解决了中厚板矫直力学模型中涉及的变形抗力值的确定问题。
6、通过对矫直机压下系统机构分析,提出了机械+液压的压下系统。其压下机构由压下螺丝螺母、双球面垫、短程伺服缸、活动横梁及滑板组组成,对系统的运动机构研究表明：压下机构由7个连杆和一个基础件组合,约束有三个定轴滑动副C、六个球面副S、空间高副H组成的空间机构,该机构为没有公共约束的多封闭环空间机构,自由度为6,有可靠确定的运动状态,能实现矫直工艺前后倾、左右倾、垂直升降的要求。
7、通过对对开式弯辊机构及整个压下机构的运动分析,研究表明：对开式弯辊机构的压下机构的自由度等于机构主动件的数目,整个机构有预期的确定的运动。压下位置关键点—铰接点的垂直位移、水平位移随上压力框架转角增加而增加,其中铰接点的垂直位移与压力框架转角关系为指数关系；铰接点的水平位移与压力框架转角关系近似为线性关系。。
8、通过建立上辊系及支撑机构等效有限元模型研究其应力／应变特征,结果表明：矫直辊辊形呈抛物线分布,其弹跳刚度为4.9×104N／mm、弯曲刚度为6.92×104N／mm；压缩变形分布也为抛物线分布,其中心比边部压缩大31.6%。
全文通过中厚板辊式矫直过程的研究,为实现第三代中厚板辊式矫直机国产化提供了理论依据。对中厚板矫直理论研究和具有自主知识产权的大型中厚板矫直机的开发及研制,在提高我国重大装备的制造能力、提高我国中厚板的质量和竞争力方面具有重要的现实意义和理论意义。
The plate leveller is important equipment of plate mill, and is key to productivity、flatness、residual stress of plate. In recent years, the customers have increasingly demands for the flatness tolerance of plate. Particularly, after TMCP technology has been widely used, plate leveller with high strength and stiffness, multi-function and advanced automation are required due to the fact that levelling temperature is lowered and yield strength of materials is increased. There is gap in perfect levelling model and automation between domestic and international.
Aimed at plate levelling model and the key relative technology, the paper developed analytical model of plate levelling process, Fifteen_roller combination leveller, the more key relative technology, by geometricanalysis, FEM simulating and experiment. Main content of the paper are introduced below:
1) The 15-roll combination leveler is designed for high strength plate leveling. Its specific roll structure could expand the thickness range of leveling plate steel. When leveling medium plate with thin scale, such 15-roll combination leveler adopted parallel leveling and expanding leveling technologies to improve the leveling precision of plate steel, as well as to expand the capacity range of material strength on leveller. The result is obtain the the parallel leveling is feasible by optimization of rollers parameter. Finally, the rollers parameter data is give that the the parallel leveling is feasible.
2) The normal operation is the key problem of combination leveler. The bite stage of plate is kernel by geometric analysis and the paper give the stabilization condition of the bite of plate in leveling. Because there is transition roller in combination leveler, the relative bite stage of plate have stabilization problem. The optimization of rollers parameter is gived to resolve the question.
3) The traditional calculation of levelling process was based on analysis of static beam. And it do not meet to need of advanced automation leveler. Taking account of different effects on work hardening and neutral layer displacement, the calculation model of levelling process is developed.by the calculation mode, the technology of Deficient deformation and 15-roll combination leveler is bring on. Due to limits of leveling machine's ability, it is difficulty that leveling heavy plate of high deformation resistance. The Deficient deformation Leveling model in heavy plate may amend profile shape in effect. In the model it is adopted that counter bend curvature Cw is less than rebound limit curvature Ct, and the residual curvature's distribution Cc is homology and is less than original curvature C0.The model reduce power of leveling and extend range of deformation resistance byl/4～1/3. The parallel leveling scheme is different to tradition model in the 15-roll combination leveller. The small roll system of the combination leveller makes work piece produce the same bending deformation with larger bending curvature, making the range of residual curvature rapidly decrease The large roll system of the combination leveler makes work piece produce the same bending deformation with smaller bending curvature and continuous small deformation, and the residual curvature could be gradually decreased.
4) Evolvement of plate wave in level are studied in this paper using both analytic geometry and FEM.The analytic geometry and simulated results show that the relative accurate results could be obtained between analytic geometry and simulated results. It is possible that the roll leveler maybe smooth wave of plate and enhance the flatness of plate. Tt is occur that the offset of stress and strain layer in the level init. The effect of wave level is exist in the first and second level unit, and the flatness of plate is increased in sequel level unit. The result show that the increasing the entance intermesh is a means of increasing flatness of plate.
5)The relate key technology is pledge to the flatness tolerance of plate and Productivity. The process automation model system, screw down system and rolls' deformation are investigated, the result indicate the self-learning deformation resistance mode is applicable to calculation of levelling process, the servo screw down system and it's DOF model is developed to suiting to levelling process, the top rolls and cabinet's compress rigidity is 4.9 X 104N/mm, bend rigidity is 6.92 X 104N/mm.
本文以某钢铁公司不锈钢热处理线3000mm十五辊组合矫直机的开发设计项目和其他热处理矫直机、冷矫直机开发设计项目为依托,对中厚板矫直理论及计算模型、组合矫直机关键技术和其它第三代矫直机关键技术进行研究,得出以下结论：
1、十五辊矫直机为高强度板设计,其核心技术是在高强薄板矫直时,采用平行矫直方案和辊系间张力技术,提高矫直精度,扩大矫直板材的材料强度范围。通过对矫直方案影响因素研究表明,在组合矫直机中实施平行矫直方案是可行性的；并且通过建立组合矫直大小辊系参数优化目标、优化约束条件,采用数值计算方法得出了组合矫直机可取辊系参数系列。
2、组合矫直机薄规格板材穿带问题为矫直过程中板材咬入问题。通过几何解析分析,提出了矫直过程中板材穿带咬入的基本条件,并推导咬入参数接触角α。与组合矫直机中间过渡辊辊系参数相关三个咬入参数接触角决定了组合矫直机薄板穿带运行稳定性。通过分析建立中间过渡辊相关辊系参数优化的数学模型,采用复合单纯形法对其进行求解,保证了组合矫直机穿带稳定。
3、建立截面分层的矫直内弯矩算法,得到矫直过程中截面上各种应力＼应变。并通过上述矫直计算模型,进一步提出了不充分变形矫直工艺、十五辊组合矫直机工艺方案。研究表明,不充分变形矫直工艺不同于现有矫直工艺，适用于厚板矫直过程。采用不充分变形多道次矫直工艺方案,扩大了矫直范围,可矫轧件变形抗力极限提高了1／4～1／3。组合矫直机辊系有别于普通矫直机辊系,在这种组合辊系和平行矫直方案的矫直过程明显不同于等辊距辊系倾斜的矫直方案。当采用平行矫直方案,相同的压下量在不同的辊系中使板材的弯曲程度不同。组合矫直前面的小辊系使轧件得到大的弯曲曲率相同弯曲变形,使残余曲率的范围快速减小。组合矫直后面的大辊系使轧件得到小的弯曲曲率相同弯曲变形,逐步减小残余曲率的数值。
4、由于矫直辊的作用,矫直单元对浪型压缩变形产生的拉伸区和压缩区,拉伸区和压缩区的应力／应变叠加弯曲变形后,产生应力中性层、应变中性层偏移。中性层的偏移和残余应变使不同部位的纵向纤维产生拉伸和压缩,是浪型矫直的根本原因。模拟结果表明：由于浪形存在矫直后,板材存在较大的残余应力,同时有横向浪形比无浪形的矫直力能参数增加。
5、通过对自学习的变形抗力模型在矫直模型中的应用研究。研究表明：模型解决了中厚板矫直力学模型中涉及的变形抗力值的确定问题。
6、通过对矫直机压下系统机构分析,提出了机械+液压的压下系统。其压下机构由压下螺丝螺母、双球面垫、短程伺服缸、活动横梁及滑板组组成,对系统的运动机构研究表明：压下机构由7个连杆和一个基础件组合,约束有三个定轴滑动副C、六个球面副S、空间高副H组成的空间机构,该机构为没有公共约束的多封闭环空间机构,自由度为6,有可靠确定的运动状态,能实现矫直工艺前后倾、左右倾、垂直升降的要求。
7、通过对对开式弯辊机构及整个压下机构的运动分析,研究表明：对开式弯辊机构的压下机构的自由度等于机构主动件的数目,整个机构有预期的确定的运动。压下位置关键点—铰接点的垂直位移、水平位移随上压力框架转角增加而增加,其中铰接点的垂直位移与压力框架转角关系为指数关系；铰接点的水平位移与压力框架转角关系近似为线性关系。。
8、通过建立上辊系及支撑机构等效有限元模型研究其应力／应变特征,结果表明：矫直辊辊形呈抛物线分布,其弹跳刚度为4.9×104N／mm、弯曲刚度为6.92×104N／mm；压缩变形分布也为抛物线分布,其中心比边部压缩大31.6%。
全文通过中厚板辊式矫直过程的研究,为实现第三代中厚板辊式矫直机国产化提供了理论依据。对中厚板矫直理论研究和具有自主知识产权的大型中厚板矫直机的开发及研制,在提高我国重大装备的制造能力、提高我国中厚板的质量和竞争力方面具有重要的现实意义和理论意义。
The plate leveller is important equipment of plate mill, and is key to productivity、flatness、residual stress of plate. In recent years, the customers have increasingly demands for the flatness tolerance of plate. Particularly, after TMCP technology has been widely used, plate leveller with high strength and stiffness, multi-function and advanced automation are required due to the fact that levelling temperature is lowered and yield strength of materials is increased. There is gap in perfect levelling model and automation between domestic and international.
Aimed at plate levelling model and the key relative technology, the paper developed analytical model of plate levelling process, Fifteen_roller combination leveller, the more key relative technology, by geometricanalysis, FEM simulating and experiment. Main content of the paper are introduced below:
1) The 15-roll combination leveler is designed for high strength plate leveling. Its specific roll structure could expand the thickness range of leveling plate steel. When leveling medium plate with thin scale, such 15-roll combination leveler adopted parallel leveling and expanding leveling technologies to improve the leveling precision of plate steel, as well as to expand the capacity range of material strength on leveller. The result is obtain the the parallel leveling is feasible by optimization of rollers parameter. Finally, the rollers parameter data is give that the the parallel leveling is feasible.
2) The normal operation is the key problem of combination leveler. The bite stage of plate is kernel by geometric analysis and the paper give the stabilization condition of the bite of plate in leveling. Because there is transition roller in combination leveler, the relative bite stage of plate have stabilization problem. The optimization of rollers parameter is gived to resolve the question.
3) The traditional calculation of levelling process was based on analysis of static beam. And it do not meet to need of advanced automation leveler. Taking account of different effects on work hardening and neutral layer displacement, the calculation model of levelling process is developed.by the calculation mode, the technology of Deficient deformation and 15-roll combination leveler is bring on. Due to limits of leveling machine's ability, it is difficulty that leveling heavy plate of high deformation resistance. The Deficient deformation Leveling model in heavy plate may amend profile shape in effect. In the model it is adopted that counter bend curvature Cw is less than rebound limit curvature Ct, and the residual curvature's distribution Cc is homology and is less than original curvature C0.The model reduce power of leveling and extend range of deformation resistance byl/4～1/3. The parallel leveling scheme is different to tradition model in the 15-roll combination leveller. The small roll system of the combination leveller makes work piece produce the same bending deformation with larger bending curvature, making the range of residual curvature rapidly decrease The large roll system of the combination leveler makes work piece produce the same bending deformation with smaller bending curvature and continuous small deformation, and the residual curvature could be gradually decreased.
4) Evolvement of plate wave in level are studied in this paper using both analytic geometry and FEM.The analytic geometry and simulated results show that the relative accurate results could be obtained between analytic geometry and simulated results. It is possible that the roll leveler maybe smooth wave of plate and enhance the flatness of plate. Tt is occur that the offset of stress and strain layer in the level init. The effect of wave level is exist in the first and second level unit, and the flatness of plate is increased in sequel level unit. The result show that the increasing the entance intermesh is a means of increasing flatness of plate.
5)The relate key technology is pledge to the flatness tolerance of plate and Productivity. The process automation model system, screw down system and rolls' deformation are investigated, the result indicate the self-learning deformation resistance mode is applicable to calculation of levelling process, the servo screw down system and it's DOF model is developed to suiting to levelling process, the top rolls and cabinet's compress rigidity is 4.9 X 104N/mm, bend rigidity is 6.92 X 104N/mm.
引文
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