高碳耐磨钢球热处理工艺及相关理论研究
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摘要
本文采用现场热处理工艺实验、奥氏体再结晶理论分析和淬火温度场数值分析相结合的方法，研究了PD3高碳耐磨钢球的生产工艺和性能，制定出了适应大批量生产的钢球热处理工艺，并最终获得了质量优异的PD3高碳耐磨钢球。
为了寻求高碳耐磨钢球的理想生产工艺参数，优化耐磨钢球的生产工艺，本文设计了高碳钢在不同条件下的热处理工艺，并分别进行了现场生产实验与实验室实验。为此应用Gleeble－1500D热模拟机模拟高碳钢在不同条件下的高温形变热处理过程。测定各种工艺下的真应力－应变曲线，观察了奥氏体的动态再结晶情况,研究了变形温度与变形速率对奥氏体动态再结晶过程的影响，并结合再结晶动力学理论进行分析，得到了理想的热处理工艺，生产出了具有较高硬度和冲击韧性的钢球产品。
为了控制和进一步提高钢球质量，作者编制了相关程序，对钢球淬火过程中温度场进行模拟，并给出了此软件的一些计算结果，模拟计算结果与实验数据吻合较好。
In this paper, properties and production process of PD3 high carbon wearable steel ball have been studied by using a combination of experimental, theoretical and numerical analysis. A production process meeting the requirements of mass production has been designed; by this production technique high quality steel ball has been successfully produced.
In order to obtain the best parameters of production process of steel ball and further optimize the production technique, the heat treatment of high carbon steel under different conditions has been carried out in both laboratory and production line. High-temperature thermomechanical treatment of high carbon steel under different conditions has been carried out on Gleeble-1500D. The true strain-stress curve of high carbon steel has been obtained. The dynamic recrystallization of Austenite has been investigated, and the effect of deformation temperature and deformation rate on the dynamic recrystallation has been also studied. The results show that the steel ball gets higher hardness and toughness when forged at 1050℃ at a high deformation rate.
In order to further improve the quality of the steel ball, special software has been developed, to simulate the temperature field of the steel ball when it is being quenched; the results calculated by the software agreed well with the theoretical analysis. Finally some numerical examples about the software are presented.
为了寻求高碳耐磨钢球的理想生产工艺参数，优化耐磨钢球的生产工艺，本文设计了高碳钢在不同条件下的热处理工艺，并分别进行了现场生产实验与实验室实验。为此应用Gleeble－1500D热模拟机模拟高碳钢在不同条件下的高温形变热处理过程。测定各种工艺下的真应力－应变曲线，观察了奥氏体的动态再结晶情况,研究了变形温度与变形速率对奥氏体动态再结晶过程的影响，并结合再结晶动力学理论进行分析，得到了理想的热处理工艺，生产出了具有较高硬度和冲击韧性的钢球产品。
为了控制和进一步提高钢球质量，作者编制了相关程序，对钢球淬火过程中温度场进行模拟，并给出了此软件的一些计算结果，模拟计算结果与实验数据吻合较好。
In this paper, properties and production process of PD3 high carbon wearable steel ball have been studied by using a combination of experimental, theoretical and numerical analysis. A production process meeting the requirements of mass production has been designed; by this production technique high quality steel ball has been successfully produced.
In order to obtain the best parameters of production process of steel ball and further optimize the production technique, the heat treatment of high carbon steel under different conditions has been carried out in both laboratory and production line. High-temperature thermomechanical treatment of high carbon steel under different conditions has been carried out on Gleeble-1500D. The true strain-stress curve of high carbon steel has been obtained. The dynamic recrystallization of Austenite has been investigated, and the effect of deformation temperature and deformation rate on the dynamic recrystallation has been also studied. The results show that the steel ball gets higher hardness and toughness when forged at 1050℃ at a high deformation rate.
In order to further improve the quality of the steel ball, special software has been developed, to simulate the temperature field of the steel ball when it is being quenched; the results calculated by the software agreed well with the theoretical analysis. Finally some numerical examples about the software are presented.
引文
[1] Tyiecote,R.F., A History of Metallurgy,The Metals Society,London,1976.
[2] 《有色金属科学技术》编委会.有色金属科学技术.冶金工业出版社，1990 .
[3] Cotterill,p.R.,Recrystallization and GrainGrowth in Metals,Surrey University Press,London,1976.
[4] 北京钢铁学院《中国冶金简史》编写组. 中国冶金简史.科学出版社.1978:264.
[5] Czochralski,J.,Z. Metallkde. 10(1927),No.8.27.
[6] Cahn,R.W.,Hassen,p., Physcial Metallurgy,3rd Ed.,North-Holand Physcis Publishing,1983.
[7] 毛卫民, 赵新兵著. 金属的再结晶与晶粒长大. 冶金工业出版社.1994.6
[8] 俞德刚. 谈育煦著. 钢的组织强度学. 上海科技出版社，1983
[9] 刘天模. PD3珠光体重轨钢成分、工艺与组织性能之间的关系研究：[重庆大学博士学位论文]. 1999.4:2
[10] Crossley F A and Mondoolfo L F. Trans.AIME,1951,191:1143
[11] Lee M S and Terry B S.Mater. Sciand Tech. 1991,7, July:608-612
[12] Arnberg L, bacerud L and Klang H. Met. Technol.,1982,9(1):1-6
[13] 杨军, 符光寒等著. 多元贝氏体铸钢球的研究和应用. 钢铁钒钛. 第21卷第2期.2000.6:29-33
[14] 俞德刚著. 钢的强韧化机理与设计. 上海交通大学出版社. 1990.5
[15] 白宇光. 浅谈国内外钢球生产工艺装备水平.轴承.1996.No11:30
[16] 曲廷敏, 周晓文. 钢球强化处理时表面层的最佳残余应力.轴承. 1994.No9: 29-31
[17] 蒋沂萍. 原材料缺陷对钢球质量的影响. 轴承. 2002.No.8: 36-39
[18] 谢恒星, 李松仁. 磨矿条件对钢球磨损的影响. 武汉化工学院学报. V ol.22 No.1 Mar. 2000:34-36
[19] 王保振. 国外钢球制造技术简介. 轴承. 1999.No11:40-43
[20] 潘洪平, 谢水生，董申. 钢球表面质量评价系统. 轴承. 2000. No.7: 30-34
[21] 潘洪平. 钢球表面质量自动评价体系建立及应用技术的研究. 哈尔滨工业大学博士论文. 2000
[22] Luton, M.J.,Sellars,C.M., Acta Met, 17,(1969):1033
[23] Johson, W.A., Mehl, R. F., Trans. AIME, 135(1939):416
[24] Sakai, T. Jons, J.J., Acta Met, 32(1984);1033
[25] Sah, J.P., Richardson, G.J., Sellars. C.M., Indian J. Technol, 11 (1973):445
[26] St?we, H.P., Ortner, B., Met. Sci, 8 (1974),:161
[27] Sandstr?m, R.,Lagneborg, R., Acta. Met.,23(1975):387
[28] S.Sakui, W.Roberts, in "Defomation, Pressing, and Structure",edited by George Krauss,1982,pl09T.Skai and K.Takeishi, Tetsu-to-Hagane,Vol 62,1976:856
[29] J.J.Jons, C.M.Sellars and W.J.McG. Trgert, Met Rev., Vol 14, 1969:l
[30] J.J.Jons and T. Sakai, in "Deformation, Processing, and Structure ", edited by Gorge Krauss, 1982:185
[31] S.Sakui, T.Sakai and K.Takeishi, Tetsu-to-Hangane, Vol 62,1976:856
[32] S.Sakui and T.Sakai, Tessu-to-Hangane, Vol 63, 1977:285
[33] S.Sakui, T.Sakai and K.Takeishi, Trans. Iron and steel Inst .Japan, Vol 17,1977:718
[34] W. Roberts, in“Deformation,Processing,and Structure”,edited by George Krauss,1982:p109
[35] K. Tsukzaki and et al,JIM., Vol 31,1990:983
[36] I.Valeyev, R.Kaibyshev and et al, in "Proc. Of Int. Congress 1989: Intergranular and Interphase Boundaries in Materials", J.de Physique (Paris) Cotloque,Vol cl,No.1:673
[37] M. E. Kassner, Metallurgical Transaction A, Vol20A,No.10,1989:2182
[38] 高飞，徐有容. 金属学报，Vol 24,1988:195
[39] L. Blaze and A. Korbel, Materials Science and Techoloyg, Vol 25,1989:1186
[40] L. Blaze, in "Proc. Of Int. 7th Riso Int. Sym. on Metallyrgy and Materials Science, Roskilde (Den-maqk)", 1986,Sept.8-12:221
[41] L. blaze,Archiwum Hutnictwa, Vol 32,1987:213
[42] M. Suery and B. Baudelet,J. ofMater. Sci., Vol 8,1973:363
[43] H. S.Ying and G. Guriwitze and A. K. Mukherjee, Matereials Transactions, JIM,Vol 32,1991:465
[44] 阎承沛. 微型机算计在热处理领域内的应用. 金属热处理. 1985.10
[45] 潘健生等. 淬火过程中计算机模拟研究的若干进展. 金属热处理. 1998.12: 30-31
[46] 王文成等. 基于神经网络的气体渗碳碳势测定. 金属热处理. 1998. 1: 11-13
[47] 王振清，文武. 热处理工艺智能控制. 金属热处理. 1998.7:24-26
[48] 潘健生. 胡明娟. 计算机模拟与热处理智能化. 金属热处理. 1998,7: 21-23
[49] 胡明娟等. 电子计算机在我国热处理领域中的应用. 金属热处理. 1996.1: 21-22
[50] Nakonieczany A, et al. 气体渗碳的计算机控制－一种可行的替代渗碳方法. 金属热处理. 1998.3: 44-49
[51] 邱大年.阎承沛等. 计算机在材料科学中的应用. 北京：北京工业大学出版社,1990
[52] 刘迨. 我国热处理的现状与未来. 金属热处理. 1996.1:8
[53] 盛光敏.李远睿. 攀钢集团钢城企业总公司钢球厂钢球生产工艺研究报告. 2001.9
Cotterill, p., Mould, p. R., R.ecrystallization and Grain Growth in Metals, Surrey University
[54] Press, London,1976
[55] Bollmann, W., Crystal Defects and Crystalline Interface, Springer Verlag, Berlin, 1970:125
[56] ASM, Metals Handbook,8th Edition, 8 (1973),:213
[57] Gottstein, G.,Zabardjadi,D., Mecking, H., Met. Sci, 13 (1979) :223
[58] 石德珂著. 位错与材料强度. 西安交通大学出版社. 1988
[59] 张伟民, 潘健生,钱初钧,李勇军,张戈.热处理数值模拟与远程服务.材料热处理学报.2001,3:60-65
[60] 顾剑锋,潘健生,胡明娟. 淬火过程计算机模拟和应用.金属热处理 2000,5: 35-39
[61] 田东,胡明娟,潘健生.淬冷过程中三维传热的数值模拟.兵器材料科学与工程.1998,7: 28-31
[62] 顾剑锋,潘健生,胡明娟. 冷扎辊过程数值模拟的研究.金属热处理学报.1999,6:1-7
[63] 田东,胡明娟,潘健生. T8钢淬火过程温度场计算和实验 .上海交通大学学报.1998,2:109
[64] 朱启惠. 刘云旭等. 合金渗碳钢件锻造余热等温正火工艺的计算机专家系统. 金属热处理. 1998.7: 1-2
[65] 杨世铭. 传热学. 高等教育出版社. 1999.10
[66] 盛光敏. PD3钢轨钢接触疲劳性能及机理研究: [博士学位论文]. 重庆大学 1999.2: [博士学位论文]. 重庆大学 1999.2
[2] 《有色金属科学技术》编委会.有色金属科学技术.冶金工业出版社，1990 .
[3] Cotterill,p.R.,Recrystallization and GrainGrowth in Metals,Surrey University Press,London,1976.
[4] 北京钢铁学院《中国冶金简史》编写组. 中国冶金简史.科学出版社.1978:264.
[5] Czochralski,J.,Z. Metallkde. 10(1927),No.8.27.
[6] Cahn,R.W.,Hassen,p., Physcial Metallurgy,3rd Ed.,North-Holand Physcis Publishing,1983.
[7] 毛卫民, 赵新兵著. 金属的再结晶与晶粒长大. 冶金工业出版社.1994.6
[8] 俞德刚. 谈育煦著. 钢的组织强度学. 上海科技出版社，1983
[9] 刘天模. PD3珠光体重轨钢成分、工艺与组织性能之间的关系研究：[重庆大学博士学位论文]. 1999.4:2
[10] Crossley F A and Mondoolfo L F. Trans.AIME,1951,191:1143
[11] Lee M S and Terry B S.Mater. Sciand Tech. 1991,7, July:608-612
[12] Arnberg L, bacerud L and Klang H. Met. Technol.,1982,9(1):1-6
[13] 杨军, 符光寒等著. 多元贝氏体铸钢球的研究和应用. 钢铁钒钛. 第21卷第2期.2000.6:29-33
[14] 俞德刚著. 钢的强韧化机理与设计. 上海交通大学出版社. 1990.5
[15] 白宇光. 浅谈国内外钢球生产工艺装备水平.轴承.1996.No11:30
[16] 曲廷敏, 周晓文. 钢球强化处理时表面层的最佳残余应力.轴承. 1994.No9: 29-31
[17] 蒋沂萍. 原材料缺陷对钢球质量的影响. 轴承. 2002.No.8: 36-39
[18] 谢恒星, 李松仁. 磨矿条件对钢球磨损的影响. 武汉化工学院学报. V ol.22 No.1 Mar. 2000:34-36
[19] 王保振. 国外钢球制造技术简介. 轴承. 1999.No11:40-43
[20] 潘洪平, 谢水生，董申. 钢球表面质量评价系统. 轴承. 2000. No.7: 30-34
[21] 潘洪平. 钢球表面质量自动评价体系建立及应用技术的研究. 哈尔滨工业大学博士论文. 2000
[22] Luton, M.J.,Sellars,C.M., Acta Met, 17,(1969):1033
[23] Johson, W.A., Mehl, R. F., Trans. AIME, 135(1939):416
[24] Sakai, T. Jons, J.J., Acta Met, 32(1984);1033
[25] Sah, J.P., Richardson, G.J., Sellars. C.M., Indian J. Technol, 11 (1973):445
[26] St?we, H.P., Ortner, B., Met. Sci, 8 (1974),:161
[27] Sandstr?m, R.,Lagneborg, R., Acta. Met.,23(1975):387
[28] S.Sakui, W.Roberts, in "Defomation, Pressing, and Structure",edited by George Krauss,1982,pl09T.Skai and K.Takeishi, Tetsu-to-Hagane,Vol 62,1976:856
[29] J.J.Jons, C.M.Sellars and W.J.McG. Trgert, Met Rev., Vol 14, 1969:l
[30] J.J.Jons and T. Sakai, in "Deformation, Processing, and Structure ", edited by Gorge Krauss, 1982:185
[31] S.Sakui, T.Sakai and K.Takeishi, Tetsu-to-Hangane, Vol 62,1976:856
[32] S.Sakui and T.Sakai, Tessu-to-Hangane, Vol 63, 1977:285
[33] S.Sakui, T.Sakai and K.Takeishi, Trans. Iron and steel Inst .Japan, Vol 17,1977:718
[34] W. Roberts, in“Deformation,Processing,and Structure”,edited by George Krauss,1982:p109
[35] K. Tsukzaki and et al,JIM., Vol 31,1990:983
[36] I.Valeyev, R.Kaibyshev and et al, in "Proc. Of Int. Congress 1989: Intergranular and Interphase Boundaries in Materials", J.de Physique (Paris) Cotloque,Vol cl,No.1:673
[37] M. E. Kassner, Metallurgical Transaction A, Vol20A,No.10,1989:2182
[38] 高飞，徐有容. 金属学报，Vol 24,1988:195
[39] L. Blaze and A. Korbel, Materials Science and Techoloyg, Vol 25,1989:1186
[40] L. Blaze, in "Proc. Of Int. 7th Riso Int. Sym. on Metallyrgy and Materials Science, Roskilde (Den-maqk)", 1986,Sept.8-12:221
[41] L. blaze,Archiwum Hutnictwa, Vol 32,1987:213
[42] M. Suery and B. Baudelet,J. ofMater. Sci., Vol 8,1973:363
[43] H. S.Ying and G. Guriwitze and A. K. Mukherjee, Matereials Transactions, JIM,Vol 32,1991:465
[44] 阎承沛. 微型机算计在热处理领域内的应用. 金属热处理. 1985.10
[45] 潘健生等. 淬火过程中计算机模拟研究的若干进展. 金属热处理. 1998.12: 30-31
[46] 王文成等. 基于神经网络的气体渗碳碳势测定. 金属热处理. 1998. 1: 11-13
[47] 王振清，文武. 热处理工艺智能控制. 金属热处理. 1998.7:24-26
[48] 潘健生. 胡明娟. 计算机模拟与热处理智能化. 金属热处理. 1998,7: 21-23
[49] 胡明娟等. 电子计算机在我国热处理领域中的应用. 金属热处理. 1996.1: 21-22
[50] Nakonieczany A, et al. 气体渗碳的计算机控制－一种可行的替代渗碳方法. 金属热处理. 1998.3: 44-49
[51] 邱大年.阎承沛等. 计算机在材料科学中的应用. 北京：北京工业大学出版社,1990
[52] 刘迨. 我国热处理的现状与未来. 金属热处理. 1996.1:8
[53] 盛光敏.李远睿. 攀钢集团钢城企业总公司钢球厂钢球生产工艺研究报告. 2001.9
Cotterill, p., Mould, p. R., R.ecrystallization and Grain Growth in Metals, Surrey University
[54] Press, London,1976
[55] Bollmann, W., Crystal Defects and Crystalline Interface, Springer Verlag, Berlin, 1970:125
[56] ASM, Metals Handbook,8th Edition, 8 (1973),:213
[57] Gottstein, G.,Zabardjadi,D., Mecking, H., Met. Sci, 13 (1979) :223
[58] 石德珂著. 位错与材料强度. 西安交通大学出版社. 1988
[59] 张伟民, 潘健生,钱初钧,李勇军,张戈.热处理数值模拟与远程服务.材料热处理学报.2001,3:60-65
[60] 顾剑锋,潘健生,胡明娟. 淬火过程计算机模拟和应用.金属热处理 2000,5: 35-39
[61] 田东,胡明娟,潘健生.淬冷过程中三维传热的数值模拟.兵器材料科学与工程.1998,7: 28-31
[62] 顾剑锋,潘健生,胡明娟. 冷扎辊过程数值模拟的研究.金属热处理学报.1999,6:1-7
[63] 田东,胡明娟,潘健生. T8钢淬火过程温度场计算和实验 .上海交通大学学报.1998,2:109
[64] 朱启惠. 刘云旭等. 合金渗碳钢件锻造余热等温正火工艺的计算机专家系统. 金属热处理. 1998.7: 1-2
[65] 杨世铭. 传热学. 高等教育出版社. 1999.10
[66] 盛光敏. PD3钢轨钢接触疲劳性能及机理研究: [博士学位论文]. 重庆大学 1999.2: [博士学位论文]. 重庆大学 1999.2