三辊行星轧制铜管的有限元数值模拟
摘要
本文利用有限元软件MSC．Marc对三辊行星轧机轧制水平连铸铜管坯的轧制过程进行了三维有限元数值模拟。利用刚塑性有限元法和大变形一大应变理论，并通过对辊形以及动态接触边界条件等关键技术进行的简化和有效的处理，建立了轧机的轧制模型。通过加入顶头实现了管
坯在变形区的旋转以及为防止变形过程中的网格畸变而使用了网格重划，从而建立了三辊行星轧制的数值模拟模型。
通过模拟，得到的结果：轧制后管坯横断面形状是由圆到三角形再归圆的过程；在轧制方向上，等效应力的最大值出现在管坯的最前端；等效应变、等效应变速率及温度场温度分布；轧制力、喂料小车和顶头受力分布。模拟结果与现场实测数据基本吻合，这对三辊行星轧机轧制水平连铸管坯的轧制工艺设计调整具有一定的意义和价值。
The paper analyze the plastic deformation of finite
elements simulation on three-roll planetary rolling process of cast copper tube. The three-roll planetary rolling model is
established ,which has the realistic contact condition and simplified
configuration of rollers. The mesh system of the whole workpiece
is created using three-dimensional tetrahedron element.
Mesh rezoning procedure is adopted to avoid the error of the
element turning out inside. The numerical results are btained,
such as the configuration of the workpiece which is
alter between circle and trangle, equivalent Von-mises stress,
plastic strain, stain velocity distribution, force of the push
plate , cushion and rolling. The results are useful in designing
and adjusting the rolling process on three-roll planetary mill of
cast copper tube.
坯在变形区的旋转以及为防止变形过程中的网格畸变而使用了网格重划，从而建立了三辊行星轧制的数值模拟模型。
通过模拟，得到的结果：轧制后管坯横断面形状是由圆到三角形再归圆的过程；在轧制方向上，等效应力的最大值出现在管坯的最前端；等效应变、等效应变速率及温度场温度分布；轧制力、喂料小车和顶头受力分布。模拟结果与现场实测数据基本吻合，这对三辊行星轧机轧制水平连铸管坯的轧制工艺设计调整具有一定的意义和价值。
The paper analyze the plastic deformation of finite
elements simulation on three-roll planetary rolling process of cast copper tube. The three-roll planetary rolling model is
established ,which has the realistic contact condition and simplified
configuration of rollers. The mesh system of the whole workpiece
is created using three-dimensional tetrahedron element.
Mesh rezoning procedure is adopted to avoid the error of the
element turning out inside. The numerical results are btained,
such as the configuration of the workpiece which is
alter between circle and trangle, equivalent Von-mises stress,
plastic strain, stain velocity distribution, force of the push
plate , cushion and rolling. The results are useful in designing
and adjusting the rolling process on three-roll planetary mill of
cast copper tube.
引文
[1] 王碧文，中国铜管生产现状及发展趋势，中国国际精密铜管技术年会文集，2003
[2] Dr.gunther voswinckel,Dr.dietmar Trauzeddel,Latest Technological Developments in the Production of Copper and Copper Alloy Tubes,中国国际精密铜管大会技术年会文集，2003
[3] Mauri Rantanen, Klemetti and Heikki Knaapi Outokumpu Engeering Contractors ,Oy.Finlond, Cast and Roll-a Advanced Method for theFabrication of Seamless Coppor Tubes..Paper presented at COPPER’90 Vasteras Sweden.
[4] 郭庆荣，沈家刚，三辊行星轧机的运动及动力分析，重型机械，1995，2，31-34。
[5] T.Sieke等.三辊行星轧机（PSW）轧管研究.国外钢铁，1990年第五期：50—54
[6] H.Garter.三辊行星轧机（PSW）轧制无缝管的试验研究. 国外钢铁.1991年第二期：48 —54
[7] 项德，三辊行星轧机轧制力能参数的研究计算，冶金设备，1990年第10期。
[8] 项德，三辊行星轧机 传动原理，冶金设备，1988年第3期。
[9] 童隆长，塑性加工过程有限元法模拟的现状和困难，塑性工程学报，2002，4
[10] K.Aoyagi,K.Ohta,Material deformation,rolling load and torque in 3-roll planetary mill,J.JSTP 24(273)(1983),1039-1047
[11] T.Nishio,T.Noma,S.Karashige,H.Hino,T.Tsuta,K.Kadota,Development of three-roll planetary mill(PSW),Kawasaki Stell Tech.Rep.83(1995)81-90
[12] Y.M.Hwang,H.H.Hsu，G.Y.Tzou,A study of PSW rolling process using stream function,J.Mater.Process.Technol,80-81(1998)341—344
[13] Y.J.Li,Elastoplastic analtsis of high reduction machine of 3-roll planetary mill by the finite element method,Master Thesis,National Sun Yat-sen University,ROC,1995
[14] C.K.Shih,C.Hung,The finite element analysis on planetary rolling process,Proceedings of the 23rd National Conference of Theoretical and Applied Mechnics,Taiwan,ROC,1999
[15] Shyue-Jian,Yeong-Maw Hwang,Ming-Hu Chang,A three-imensional finite element analysis of the three-roll planetary mill. Journal of Materials Processing Technology123(2002)336-345
[16] T.Siebke,H.Gartner,Development of and trials with a seamless tube rolling process employing a 3-roll planetary mill(PSW),MPT Metal,Plant Technol,13(2)(1990)72-80
[17] Chih-Kang Shih,Ray-Quen Hsu,Ching hua Hung,A study on seamless tube in the panetary rolling process ,Journal of Materials Processing Technology 121(2002)273-284
[18] 曲华，三辊联合穿轧轧制过程的计算机模拟，煤矿机械，2001年第8期。
[19] W.J Ammerling,H.Brauer,Application of 3-roll technology for rolling specialty rod and bar products, Iron and Steel Enger.65(9)(1988)22-27
[20] W.J Ammerling, Kocks 3-roll technology for high precision specialty rod and bar product, MPT Metal. Plant Techol. 12(6)(1989)14-19
[21] C.Recalcati, C.Ventura, W.Rench, HRM high-reduction rolling machine, Wire Ind. 57(673)(1990)31-34
[22] Chih-Kang Shih,Chinghua Hung,Experimental and numerical analysis om three-roll planetary rolling process, Journal of Materials Processing Technology122,(2002)
[23] 李志强，斜扎理论，太原重型机械学院，1992年
[24] 李应强，PSW轧机运动分析及结构参数研究，北京钢铁学院硕士论文, 1983
[25] 青柳幸四郎，三辊行星轧机轧制负荷与金属变形研究，塑性与加工，1983年第10期。
[26] 罗大佑，行星齿轮机构，北京高等教育出版社，1984年第一版
[27] H.Marten,New Approachs in technology to increase quality and productivity, MPT Metal.Plant Technol .9(5) (1986) 39-55
[28] Chih-Kang Shih,Chinghua Hung,Ray-Quen Hsu,The finite elemrnt analysis planetary rolling process, Journal of Materials Processing Technology113,(2001)
[29] 谢启尧，三辊行星斜轧力能参数计算理论，北京科技大学硕士论文，1988
[30] 李国祯，三辊联合穿轧的工具设计，太原重型机械学院，1988
[31] 陈如欣，胡忠民，塑性有限元法及其在金属成型中的应用.重庆，重庆大学出版社.1989：3-15
[32] 胡忠，塑性有限元模拟技术的最新进展.塑性工程学报.1994，1（3）3-13
[33] P.V.Marcal, I.D.King. Elastic-Plastic Analysis of Two- Dimensional Stress Systems by the Finite Element Method. Int.J.Mech.Sci.. 1967,9: 143-155
[34] Y.Yamada,N.Yoshimura,T.Sakurai. Plastic Stress-Strain Matrix and Its Application for the Solution of Elastic-Plastic Problems by the Element Method. Int.J.Mech.Sci.. 1967,10: 343-354
[35] Yang Qingchun, Qu Shengnian, Zhou Qi, MinNaiyan, FE Simulation Method for forging System.J.of Mater.Process Technol.1987,63:678-683
[36] 郑莹，吴勇国.板材成型数值模拟进展. 塑性工程学报.1996,3(4):6-14
[37] 单德斌，吕炎，王真.金属体积成形过程三维刚塑性有限元模拟技术的研究.塑性加工学报.1997，4（3）：98-102
[38] 王连生，曹起骧，许思广.三维热耦合刚粘塑性有限元数值模拟技术的开发和应用. 塑性加工学报.1994,1(3):35-39
[39] 许沂，筒形件强旋三维数值模拟及其在钛合金冷强旋中的应用，哈尔滨工业大学博士论文，1999
[40] D.J.Hayes. Determination of Upper Bounds for Problems in Plane Stress Using Finite Element Techniques. Int.J.Mech.Sci., 1967,9(5):245-252
[41]C.H.Lee,S.Kobayashi. New Solution to Rigid-Plastic Deformation Problems Using a Matrix Method. Trans. ASME, J. Engr.Ind.,1973,95: 865-877
[42] 谢水生，王祖堂，金属塑性成形工步的有限元数值模拟，1997，9，23-28
[43] 陈火红，MARC有限元实例分析教程，机械工业出版社，2002年
[44] 周文龙，许沂，张士宏，挤压铜管坯与连铸连轧铜管坯的研究，中国国际精密铜管技术年会文集，2003
[2] Dr.gunther voswinckel,Dr.dietmar Trauzeddel,Latest Technological Developments in the Production of Copper and Copper Alloy Tubes,中国国际精密铜管大会技术年会文集，2003
[3] Mauri Rantanen, Klemetti and Heikki Knaapi Outokumpu Engeering Contractors ,Oy.Finlond, Cast and Roll-a Advanced Method for theFabrication of Seamless Coppor Tubes..Paper presented at COPPER’90 Vasteras Sweden.
[4] 郭庆荣，沈家刚，三辊行星轧机的运动及动力分析，重型机械，1995，2，31-34。
[5] T.Sieke等.三辊行星轧机（PSW）轧管研究.国外钢铁，1990年第五期：50—54
[6] H.Garter.三辊行星轧机（PSW）轧制无缝管的试验研究. 国外钢铁.1991年第二期：48 —54
[7] 项德，三辊行星轧机轧制力能参数的研究计算，冶金设备，1990年第10期。
[8] 项德，三辊行星轧机 传动原理，冶金设备，1988年第3期。
[9] 童隆长，塑性加工过程有限元法模拟的现状和困难，塑性工程学报，2002，4
[10] K.Aoyagi,K.Ohta,Material deformation,rolling load and torque in 3-roll planetary mill,J.JSTP 24(273)(1983),1039-1047
[11] T.Nishio,T.Noma,S.Karashige,H.Hino,T.Tsuta,K.Kadota,Development of three-roll planetary mill(PSW),Kawasaki Stell Tech.Rep.83(1995)81-90
[12] Y.M.Hwang,H.H.Hsu，G.Y.Tzou,A study of PSW rolling process using stream function,J.Mater.Process.Technol,80-81(1998)341—344
[13] Y.J.Li,Elastoplastic analtsis of high reduction machine of 3-roll planetary mill by the finite element method,Master Thesis,National Sun Yat-sen University,ROC,1995
[14] C.K.Shih,C.Hung,The finite element analysis on planetary rolling process,Proceedings of the 23rd National Conference of Theoretical and Applied Mechnics,Taiwan,ROC,1999
[15] Shyue-Jian,Yeong-Maw Hwang,Ming-Hu Chang,A three-imensional finite element analysis of the three-roll planetary mill. Journal of Materials Processing Technology123(2002)336-345
[16] T.Siebke,H.Gartner,Development of and trials with a seamless tube rolling process employing a 3-roll planetary mill(PSW),MPT Metal,Plant Technol,13(2)(1990)72-80
[17] Chih-Kang Shih,Ray-Quen Hsu,Ching hua Hung,A study on seamless tube in the panetary rolling process ,Journal of Materials Processing Technology 121(2002)273-284
[18] 曲华，三辊联合穿轧轧制过程的计算机模拟，煤矿机械，2001年第8期。
[19] W.J Ammerling,H.Brauer,Application of 3-roll technology for rolling specialty rod and bar products, Iron and Steel Enger.65(9)(1988)22-27
[20] W.J Ammerling, Kocks 3-roll technology for high precision specialty rod and bar product, MPT Metal. Plant Techol. 12(6)(1989)14-19
[21] C.Recalcati, C.Ventura, W.Rench, HRM high-reduction rolling machine, Wire Ind. 57(673)(1990)31-34
[22] Chih-Kang Shih,Chinghua Hung,Experimental and numerical analysis om three-roll planetary rolling process, Journal of Materials Processing Technology122,(2002)
[23] 李志强，斜扎理论，太原重型机械学院，1992年
[24] 李应强，PSW轧机运动分析及结构参数研究，北京钢铁学院硕士论文, 1983
[25] 青柳幸四郎，三辊行星轧机轧制负荷与金属变形研究，塑性与加工，1983年第10期。
[26] 罗大佑，行星齿轮机构，北京高等教育出版社，1984年第一版
[27] H.Marten,New Approachs in technology to increase quality and productivity, MPT Metal.Plant Technol .9(5) (1986) 39-55
[28] Chih-Kang Shih,Chinghua Hung,Ray-Quen Hsu,The finite elemrnt analysis planetary rolling process, Journal of Materials Processing Technology113,(2001)
[29] 谢启尧，三辊行星斜轧力能参数计算理论，北京科技大学硕士论文，1988
[30] 李国祯，三辊联合穿轧的工具设计，太原重型机械学院，1988
[31] 陈如欣，胡忠民，塑性有限元法及其在金属成型中的应用.重庆，重庆大学出版社.1989：3-15
[32] 胡忠，塑性有限元模拟技术的最新进展.塑性工程学报.1994，1（3）3-13
[33] P.V.Marcal, I.D.King. Elastic-Plastic Analysis of Two- Dimensional Stress Systems by the Finite Element Method. Int.J.Mech.Sci.. 1967,9: 143-155
[34] Y.Yamada,N.Yoshimura,T.Sakurai. Plastic Stress-Strain Matrix and Its Application for the Solution of Elastic-Plastic Problems by the Element Method. Int.J.Mech.Sci.. 1967,10: 343-354
[35] Yang Qingchun, Qu Shengnian, Zhou Qi, MinNaiyan, FE Simulation Method for forging System.J.of Mater.Process Technol.1987,63:678-683
[36] 郑莹，吴勇国.板材成型数值模拟进展. 塑性工程学报.1996,3(4):6-14
[37] 单德斌，吕炎，王真.金属体积成形过程三维刚塑性有限元模拟技术的研究.塑性加工学报.1997，4（3）：98-102
[38] 王连生，曹起骧，许思广.三维热耦合刚粘塑性有限元数值模拟技术的开发和应用. 塑性加工学报.1994,1(3):35-39
[39] 许沂，筒形件强旋三维数值模拟及其在钛合金冷强旋中的应用，哈尔滨工业大学博士论文，1999
[40] D.J.Hayes. Determination of Upper Bounds for Problems in Plane Stress Using Finite Element Techniques. Int.J.Mech.Sci., 1967,9(5):245-252
[41]C.H.Lee,S.Kobayashi. New Solution to Rigid-Plastic Deformation Problems Using a Matrix Method. Trans. ASME, J. Engr.Ind.,1973,95: 865-877
[42] 谢水生，王祖堂，金属塑性成形工步的有限元数值模拟，1997，9，23-28
[43] 陈火红，MARC有限元实例分析教程，机械工业出版社，2002年
[44] 周文龙，许沂，张士宏，挤压铜管坯与连铸连轧铜管坯的研究，中国国际精密铜管技术年会文集，2003