三辊行星轧机轧制过程力分析
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摘要
目前,国内外金属轧制生产技术的发展趋势是：大规模生产的高效化、短流程工艺、生产线连续作业、环境污染和能耗小。三辊行星轧机是最具代表性的短流程关键设备,其优点是单道次变形量大和良好的无扭连轧特性,可用于轧制钢、有色金属和一些难变形的合金材料,在棒材、线材和管材成型中获得日益广泛的应用。就国内外三辊行星轧机的理论研究而言,虽然取得了一定的研究成果,但仍有许多问题尚待研究。本文分别用传统的理论方法和有限元仿真的方法,对轧件的变形过程和轧制力能参数进行研究。
论文简要叙述了三辊行星轧机的产生与发展、传动原理及其优点与不足。在总结前人研究设计轧机成果基础上,借助于已建立的轧件变形区微分几何模型和对轧辊与轧件几何关系的研究,详细分析了轧辊与轧件的接触面。根据卡尔曼单位压力微分求解原理,得到轧件变形区的单位压力表达式,进而推导出计算轧制力和轧制力矩的积分式,并采用数值分析的方法对其进行精确计算。根据实际轧制条件,选取适当的轧制参数,应用Visual Basic语言编程计算,获取轧制力、轧制力矩和电动机的功率。
论文根据有限元法的基础理论,推导了大变形弹塑性有限元法和显式动力学有限元法的求解过程,成功利用有限元分析软件ANSYS/LS-DYNA对三辊行星轧机轧制的弹塑性大变形过程进行有限元仿真计算。在对轧机各主要部件进行合理简化的基础上,采用坐标变换的方法,将轧辊的轴线和轧件的中心线准确地在ANSYS/LS-DYNA软件中定位,建立起轧辊与轧件的三维实体有限元模型。根据仿真数据,对轧件的形状、等效应力和应变分布、轧制负荷以及轧件速度进行分析,讨论了转化轮系传动比和螺旋运动参数,确定了轧件中性面位置。
论文采用传统的理论和编程计算轧制力能参数的方法,提高了计算效率,便于工程上的应用。基于ANSYS/LS-DYNA软件进行的有限元仿真分析,为进一步认识轧制过程中轧件的成形规律打下了基础,也为轧机设计提供了依据。
At present, the domestic and foreign metal rolling technology trend of development is:the large scale production by highly efficiency, the craft of short flow, the production line continued operation, the small environmental pollution and the low energy consumption. Three-roll planetary mill (PSW) is the most representative short flow essential equipment. The large deformation in a single pass and good capability of no-torsion continuous rolling are its merits. PSW can be used to roll steel, non-ferrous metals and hard deforming alloy material. In the formation of rod, wire-rod and tubing, it is used widely day by day. Speaking of the domestic and foreign theoretics study on PSW, although it has acquired certain research results, it still need to be studied in many respects. This paper separately uses traditional theory method and finite element method to research workpiece's deformation process and rolling force.
The paper briefly narrates emergence, development, transmission principle, merits and faults of PSW. On the basis of summarizing predecessors'research results of designing PSW, contact area has analyzed in detail with the differential geometry model and geometrical relationship research between roller and workpiece. According to the differential principle which Kalman solves unit pressure, unit pressure of the deformed area is obtained. And then the integral equation of rolling force is gotten. Finally the rolling force and rolling torque are obtained by means of numerical analysis method. On the basis of the actual rolling condition, the paper selects suitable rolling parameters and uses the software of Visual Basic to program. We can get the rolling force, the rolling torque and the power of motor.
According to the basic theory of finite element method, the solution process of big elastoplastic finite element method and explicit dynamics finite element method are deduced. The author uses triumphantly finite element analysis software ANSYS/LS-DYNA to do the elastic-plasticity large deformation process'emulational calculation of rolling process. Each major component of PSW is used to predigest the rational model for the tridimensional entity finite element model. It uses the transformation of coordinates together with the accurate position of roller axes and workpiece center line. According to the simulation data, we can analyze workpiece shape, distribution of the equivalent stress and strain, rolling force, workpiece velocity, transmission ratio of wheel train, spiral movement parameter and position of the neutral plane.
The paper uses the traditional theory and programming to calculate rolling force. This method has the merit of high computing efficiency. It is easier to be used in the engineering application. The finite element simulation analysis is based on the software of ANSYS/LS-DYNA. It can establish the foundation for the advanced realization of workpiece forming law, and offer reference to design the PSW.
论文简要叙述了三辊行星轧机的产生与发展、传动原理及其优点与不足。在总结前人研究设计轧机成果基础上,借助于已建立的轧件变形区微分几何模型和对轧辊与轧件几何关系的研究,详细分析了轧辊与轧件的接触面。根据卡尔曼单位压力微分求解原理,得到轧件变形区的单位压力表达式,进而推导出计算轧制力和轧制力矩的积分式,并采用数值分析的方法对其进行精确计算。根据实际轧制条件,选取适当的轧制参数,应用Visual Basic语言编程计算,获取轧制力、轧制力矩和电动机的功率。
论文根据有限元法的基础理论,推导了大变形弹塑性有限元法和显式动力学有限元法的求解过程,成功利用有限元分析软件ANSYS/LS-DYNA对三辊行星轧机轧制的弹塑性大变形过程进行有限元仿真计算。在对轧机各主要部件进行合理简化的基础上,采用坐标变换的方法,将轧辊的轴线和轧件的中心线准确地在ANSYS/LS-DYNA软件中定位,建立起轧辊与轧件的三维实体有限元模型。根据仿真数据,对轧件的形状、等效应力和应变分布、轧制负荷以及轧件速度进行分析,讨论了转化轮系传动比和螺旋运动参数,确定了轧件中性面位置。
论文采用传统的理论和编程计算轧制力能参数的方法,提高了计算效率,便于工程上的应用。基于ANSYS/LS-DYNA软件进行的有限元仿真分析,为进一步认识轧制过程中轧件的成形规律打下了基础,也为轧机设计提供了依据。
At present, the domestic and foreign metal rolling technology trend of development is:the large scale production by highly efficiency, the craft of short flow, the production line continued operation, the small environmental pollution and the low energy consumption. Three-roll planetary mill (PSW) is the most representative short flow essential equipment. The large deformation in a single pass and good capability of no-torsion continuous rolling are its merits. PSW can be used to roll steel, non-ferrous metals and hard deforming alloy material. In the formation of rod, wire-rod and tubing, it is used widely day by day. Speaking of the domestic and foreign theoretics study on PSW, although it has acquired certain research results, it still need to be studied in many respects. This paper separately uses traditional theory method and finite element method to research workpiece's deformation process and rolling force.
The paper briefly narrates emergence, development, transmission principle, merits and faults of PSW. On the basis of summarizing predecessors'research results of designing PSW, contact area has analyzed in detail with the differential geometry model and geometrical relationship research between roller and workpiece. According to the differential principle which Kalman solves unit pressure, unit pressure of the deformed area is obtained. And then the integral equation of rolling force is gotten. Finally the rolling force and rolling torque are obtained by means of numerical analysis method. On the basis of the actual rolling condition, the paper selects suitable rolling parameters and uses the software of Visual Basic to program. We can get the rolling force, the rolling torque and the power of motor.
According to the basic theory of finite element method, the solution process of big elastoplastic finite element method and explicit dynamics finite element method are deduced. The author uses triumphantly finite element analysis software ANSYS/LS-DYNA to do the elastic-plasticity large deformation process'emulational calculation of rolling process. Each major component of PSW is used to predigest the rational model for the tridimensional entity finite element model. It uses the transformation of coordinates together with the accurate position of roller axes and workpiece center line. According to the simulation data, we can analyze workpiece shape, distribution of the equivalent stress and strain, rolling force, workpiece velocity, transmission ratio of wheel train, spiral movement parameter and position of the neutral plane.
The paper uses the traditional theory and programming to calculate rolling force. This method has the merit of high computing efficiency. It is easier to be used in the engineering application. The finite element simulation analysis is based on the software of ANSYS/LS-DYNA. It can establish the foundation for the advanced realization of workpiece forming law, and offer reference to design the PSW.
引文
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[2]张明湖.行星式三辊轮辊压制程之三维有限元素法分析：[博士学位论文].高雄：国立中山大学,2001
[3]王邦文.新型轧机.北京：冶金工业出版社,1994
[4]傅文祖.大压下三辊行星轧机的进展.江苏冶金,1987,(5)：32-37
[5]陈瑛.轧机释名(一).轧钢,1989,(1)：62-63
[6]项德.三辊行星轧机传动原理.冶金设备,1988,(3)：5-9
[7]张士宏,王炳德,朱士光等.一种新型三辊旋轧试验机的设计.锻压装备与制造技术,2007,42(2)：40-42
[8]曾幼宗.三辊行星轧机的应用.钢管,1993,(5)：43-46
[9]傅文祖.三辊行星斜轧机及其运动学.冶金设备,1981,(3)：20-27
[10]丁大字.三辊行星斜轧机.冶金设备,1983,(3)：29-34
[11]赵如民.三辊行星斜轧管机的开发与应用.轧钢,1993,(2)：27-29
[12]叶绣中.三辊行星轧机.江西冶金,1984,4(1)：77-82
[13]赵强.三辊行星轧机的发展情况及其现状.特殊钢,1991,12(5)：41-46
[14]郄玉琴,何为群.三辊行星轧机轧辊寿命的研究.实用机械技术,1991,(3)：10-12
[15]Plant Engineering Division. PSW-Planetary Cross Rolling Mill.川崎重技报,1984,(82)：81-90
[16]H.Gartner. Development of and trials with a seamless tube rolling process employing a 3-roll planetary mill(PSW). Metallurgical Plant and Technology, 1990, (2):72-80
[17]W.J.Ammerling. The knocks 3-roll technology for high precision specialty rod and bar products. Metallurgical Plant and Technology,1989, (6):14-19
[18]K. Nakasuji, K. Kuroda, C. Hayashi. Development and Features of Rotary Reduction Mil. Journal of the ISIJ,1991,31(6):620
[19]傅文祖.大压下三辊行星轧机的发展概况.上海冶金设计,1989,(1)：1-17
[20]汤元艺.新型三辊轧管机.冶钢译丛,1992,(2)：22-34
[21]傅文祖.三辊行星轧机轧制无缝管.冶金设备,1984,(6)：59
[22]靳晓云.三辊行星轧机(PSW)轧管研究.钢管,1990,(5)：50-55
[23]邓楚平,黄伯云,苏玉长等.对ACR铜管生产中PSW轧制技术的研究.湖南冶金,2006,34(5)：3-6
[24]金如崧.斜轧工艺在延伸轧管阶段的进一步应用.钢管,2002,31(4)：55-57
[25]侯张宝.三辊行星斜轧机工艺及参数.冶金设备,1982,(1)：5-12
[26]张荣.三辊行星斜轧机的辊形探讨.重型机械,1983,(1)：18-23
[27]杨继宗,杨淼泉,傅文祖.三辊行星轧机样机分析.上海冶金,1979,1(1)：128-133
[28]西安重型机械研究所三辊行星轧机课题组.φ40mm三辊行星轧机实验研究.重型机械,1984,(4)：20-28
[29]张海兵,倪元相,刘晓星.行星轧机的轧件变形区微分几何模型.重型机械,2007,(3)：49-52
[30]蔡葵,陈淦.’三辊行星轧机的参数分析与提高轧件质量的途径.冶金设备,1987,(1)：18-23
[31]陈淦.三辊行星轧机辊型设计方法.重型机械,1987,(3)：27-37
[32]李国祯.斜轧机轧辊辊形的计算.钢管,1990,(3)：28-32
[33]康祖立,孙元堂.三辊行星轧机辊型的理论分析.重型机械,1988,(10)：33-39
[34]张海兵,刘晓星,倪元相.行星轧机中轧辊与轧件的几何关系分析.重型机械,2007,(5)：37-41
[35]傅文祖.三辊行星斜轧机及其轧制力计算.上海金属(有色分册),1985,6(2)：13-20
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