冷拔钢丝扭转性能的研究
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摘要
随着钢丝制品行业的快速发展,钢丝韧性性能越来越受到人们的关注。扭转性能是钢丝的重要机械性能指标之一,用以表征材料的韧性性能。对扭转性能的研究是提高钢丝综合力学性能的关键。
本文以冷拔钢丝为研究对象,主要研究内容如下:
首先,分析钢丝扭转变形机理、异常断口、材料组织结构、表面质量及残余应力测量。通过宏观和微观综合分析,钢丝表面轴向残余应力值过大是影响钢丝扭转性能降低的主要因素。
其次,根据有限元理论,建立钢丝拉拔的三维模型,在实际生产的条件下采用物理测量验证有限元模型可靠性。分析金属的流动特点及钢丝残余应力的分布规律。
最后,引入混合优化方法,利用有限元模拟和神经网络建立正确的描述拉拔参数与钢丝表面轴向残余应力关系的映射模型,采用遗传算法进行优化设计,优化钢丝拉拔过程参数。
通过对冷拔钢丝扭转性能研究,混合优化后钢丝表面的轴向残余应力降低67.6%,优化效果明显。使钢丝表面的裂纹不易在轴向应力下扩展破坏,因此提高了冷拔钢丝的扭转性能,保证钢丝的综合力学性能,为同类问题的解决提供了借鉴。
With the rapid development of steel wire industry, more and more attention has been paid to the toughness of steel wire. Torsion performance is an important mechanical indicator, which is often used to describe the material toughness properties. Therefore, the research of torsion is the key to improve its comprehensive mechanical properties.
In this paper, cold drawn steel wire is selected as the research object, and the main research contents are as follows:
Firstly, the wire torsion deformation mechanism, abnormal fracture, material organizational structure, surface quality and residual stress are investigated in detail. By macro and micro analyses, the primary factor of degrading torsion performance is oversized axial residual stress in the surface.
Secondly, according to the finite element theory, the three-dimensional modeling of wire drawing is established, and the finite element model is verified by using physical measurements in the actual production conditions. Metal flow characteristics and residual stress distribution in the steel wire are finally analyzed explicitly.
Last, hybrid optimization method is introduced in present work. Finite element simulation and BP neural network are combined together to build the non-linear mapping relations between residual stress and forming parameters. During the process of optimization, genetic algorithm is used to obtain the wire drawing process parameters.
Through studying the torsion performance of cold drawn steel wire, the axial residual of steel wire surface is forced to be decreased by 67.6%, and hybrid optimized effect is fully perfect. The defects of steel wire surface do not expand easily under the residual stress. Therefore, Torsion performance is enhanced greatly, and the comprehensive mechanical property is guaranteed. It also provides helpful references for the similar problems.
本文以冷拔钢丝为研究对象,主要研究内容如下:
首先,分析钢丝扭转变形机理、异常断口、材料组织结构、表面质量及残余应力测量。通过宏观和微观综合分析,钢丝表面轴向残余应力值过大是影响钢丝扭转性能降低的主要因素。
其次,根据有限元理论,建立钢丝拉拔的三维模型,在实际生产的条件下采用物理测量验证有限元模型可靠性。分析金属的流动特点及钢丝残余应力的分布规律。
最后,引入混合优化方法,利用有限元模拟和神经网络建立正确的描述拉拔参数与钢丝表面轴向残余应力关系的映射模型,采用遗传算法进行优化设计,优化钢丝拉拔过程参数。
通过对冷拔钢丝扭转性能研究,混合优化后钢丝表面的轴向残余应力降低67.6%,优化效果明显。使钢丝表面的裂纹不易在轴向应力下扩展破坏,因此提高了冷拔钢丝的扭转性能,保证钢丝的综合力学性能,为同类问题的解决提供了借鉴。
With the rapid development of steel wire industry, more and more attention has been paid to the toughness of steel wire. Torsion performance is an important mechanical indicator, which is often used to describe the material toughness properties. Therefore, the research of torsion is the key to improve its comprehensive mechanical properties.
In this paper, cold drawn steel wire is selected as the research object, and the main research contents are as follows:
Firstly, the wire torsion deformation mechanism, abnormal fracture, material organizational structure, surface quality and residual stress are investigated in detail. By macro and micro analyses, the primary factor of degrading torsion performance is oversized axial residual stress in the surface.
Secondly, according to the finite element theory, the three-dimensional modeling of wire drawing is established, and the finite element model is verified by using physical measurements in the actual production conditions. Metal flow characteristics and residual stress distribution in the steel wire are finally analyzed explicitly.
Last, hybrid optimization method is introduced in present work. Finite element simulation and BP neural network are combined together to build the non-linear mapping relations between residual stress and forming parameters. During the process of optimization, genetic algorithm is used to obtain the wire drawing process parameters.
Through studying the torsion performance of cold drawn steel wire, the axial residual of steel wire surface is forced to be decreased by 67.6%, and hybrid optimized effect is fully perfect. The defects of steel wire surface do not expand easily under the residual stress. Therefore, Torsion performance is enhanced greatly, and the comprehensive mechanical property is guaranteed. It also provides helpful references for the similar problems.
引文
[1]文一元,沈世续.对我国金属制品生产工艺装备发展的意见[J].金属制品,1999,25(1):1～4
[2]赵继红.国内外高速线材轧制技术发展浅析[J].轧钢,1998(4):47～51
[3]康昕.我国钢帘线的生产情况及国内外钢帘线生产技术[J].钢铁技术,2006(6):1～4
[4]王宝玉,宋为.我国胎圈钢丝供需现状和展望[J].轮胎工业,2004(6):323～326
[5]戴宝昌.重要用途线材制品生产新技术[M].北京:冶金工业出版社,2001
[6]陈其安.“从盘条到丝材及丝制品”——国际会议及欧洲盘条与高强钢丝研发现状简介[J].中国冶金,2003(12):44～45
[7] Y.H.Xu, J.H.Peng,L.Fang. Nano-crystallization of steel wire and its wear behavior[J]. Materials Science and Engineering A. 2008 (483～484): 688～691
[8]李志深.钢丝生产工艺下册[M].湘潭:湘潭钢铁公司情报室,1992
[9]崔忠圻.金属学与热处理[M].北京:机械工业出版社,2000
[10] W.Van Raemdonck,I.Lefever,U.D Haene. Torsion Test as A Tool for High StrengthWire Evaluation[J].Wire Journal International.1994 (6):68～75
[11] A.Kagawa, T. Okamoto, H.Matsumoto. Young's Modulus and Thermal Expansion of Pure Iron-cementite Alloy Castings[J]. Acta Metallurgia.1987(4):797～803
[12]黄明志.GCr15钢不同回火态扭转流变硬化行为和组织强度研究[J].机械工程学报,1994,V30(5):94～99
[13] M.B. Chul, J.N. Won. Void Formation at Large Drawing Strain Pearlitic Steel wires. Wire Journal International[J].1997(7):102～105
[14]崔发明.高碳钢丝扭转断裂原因分析[J].金属制品2007,33(3):39～41
[15]王自森.拉拔时发热现象的探讨[J].金属制品,2005,11(4):14～16
[16]贺吉良.直接水冷拉丝模在钢丝生产中的应用[J].金属制品2001,27(5), 39～41
[17]邓世均.提高65Mn碳素弹簧钢丝扭转性能新工艺[J].四川冶金,2001 (4):39～41
[18]左伟,杨红燕.中碳钢丝热处理工艺及拉拔工艺对其性能的影响[J].金属材料,2005(6):83～87
[19]秦万信.钢丝的高速拉拔[J].金属制品,1990,25(2):28～31
[20] J.Gil Sevillano. Cleavage Limited Maximum Strength of Work-hardened B.C.C Polycristals[J].Acta Metallurgia.1986(34):1473～1485
[21]文一元.如何提高模具使用寿命[J].金属制品,1991,2l(l):15～19
[22]周健民,李建川.钢丝扭转试验的轴向拉力对其扭转次数的影响[J].物理测试,1992(4):50～53
[23] B.Goest, A. Martin-Meizoso,J.Gil-Sevillano. Fragmentation of As-draw Pearlitic Steel Wire During Torsion Tests [J]. Engineering Fracture Mechanics. 1998, 60(3): 255～272
[24] Y. Suzuki,M. Asakawa,H.Mizuno et al. Generating a mechanism of delamination in high carbon steel wire by experimental drawing[J].Wire Journal International,2005 (10):70～72
[25] J.K.Hallgarth. Torsion Ductility of High Carbon Steel Wire [J]. Iron making and Steel making.1995,22(3):211～222
[26] P. F. Willemse,B.P. Naughton,C.A.Verbraaka.X-ray residual stress measurements on cold-drawn steel wire[J].Materials Science and Engineering,1982(56):25～38.
[27] H.Overstam. The influence of bearing geometry on the residual stress state in cold drawn wire, analysed by the FEM[J].Materials Processing Technology,2006 (171):446～450
[28] D.K.Roberts, A.A.Wells. The Velocity of Brittle Fracture [J]. Engineering, 1984 (171):820～821
[29]何吉林.钢丝生产[M].北京:兵器工业出版社,2001
[30]崔约贤,王长利.金属断口分析[M].哈尔滨:哈尔滨工业大学出版社.1998
[31]汪守朴.金相分析基础[M].北京:机械工业出版社.1998
[32]张定锉,何家文.材料中残余应力的X射线衍射分析和作用[M].西安:西安交通大学出版社,1999
[33]赵敏,聂明芬,蔡磊.钢丝的扭转性能分析[J].金属制品,2007,33(6):34～36
[34]束德林.金属力学性能[M].北京:机械工业出版社,1999
[35]王世斌,亢一澜.材料力学[M].北京:高等教育出版社,2008
[36]黄明志.金属力学性能[M].西安:西安交通大学出版社,1986
[37]徐忠良.大跨度桥梁缆索用SWRS82B热轧盘条的组织与钢丝扭转性能研究[D].东南大学硕士论文,2006:20～35.
[38]弗里德曼.金属机械性能第一分册[M].北京:机械工业出版社,1982
[39]崔发明.高碳钢丝扭转断裂原因分析[J].金属制品,2007,33(3):39～41
[40]金属机械性能编写组.金属机械性能[M].北京:机械工业出版社,1986
[41]刘全坤.材料成形基本原理[M].北京:机械工业出版社,2005
[42] J.N.Won, M.B.Chul. Void initiation and micro-structural changes during wiredrawing of pearlitic steels[J].Materials Science and Engineering A, 1995 (203): 278～285
[43]鞍钢钢铁研究所,丘利,胡玉和.X射线衍射技术及设备[M].北京:冶金工业出版社,2003
[44]俞汉清,陈金德.金属塑性成形理论[M].北京:机械工业出版社,1999
[45]李亚智,赵美英,万小朋.有限元法基础与程序设计[M].北京:科学出版社,2004
[46]孟凡中.弹塑性有限变形理论和有限元方法[M].北京:清华大学出版社,1985
[47]冯果忱.非线性方程组迭代解法[M].上海:上海科学技术出版社,1989
[48]陈献廷.硬质合金使用手册[M].北京:冶金工业出版社,1986
[49] P.Gillstr?m, M. Jarl. Wear of die after drawing of pickled or reverse bent wire rod[J]. Wear. 2007 (262):858～867
[50] M.Elices. Influence of residual stresses in the performance of cold-drawn pearlitic wires [J].Materials science,2004 (39):3889～3899
[51]胡龙飞,刘全坤,王成勇等.基于多目标优化的钢管拉拔成形过程设计[J].农业机械学报,2007,38(10):161～164
[52]陈立周.机械优化设计方法[M].北京:冶金工业出版社,2005:12～25
[53]陈魁.试验设计与分析[M].北京:清华大学出版社,2005
[54]袁曾任.人工神经元网络及其应用[M].北京:清华大学出版社,1999
[55]徐敬,王秀坤,胡家升.基于神经网络的无源多传感器属性数据关联[J].系统仿真学报2003,15(1):127～131
[56] D.F. Cook, C.T. Ragsdale, R.L. Major. Combining a neural network with a genetic algorithm for process parameter optimization [J].Engineering Applications of Artificial Intelligence,2000, 13(4):391～396
[57]雷英杰,张善文,李续武等.MATLAB遗传算法工具箱及应用[M].西安:西安电子科技大学出版社,2005
[2]赵继红.国内外高速线材轧制技术发展浅析[J].轧钢,1998(4):47～51
[3]康昕.我国钢帘线的生产情况及国内外钢帘线生产技术[J].钢铁技术,2006(6):1～4
[4]王宝玉,宋为.我国胎圈钢丝供需现状和展望[J].轮胎工业,2004(6):323～326
[5]戴宝昌.重要用途线材制品生产新技术[M].北京:冶金工业出版社,2001
[6]陈其安.“从盘条到丝材及丝制品”——国际会议及欧洲盘条与高强钢丝研发现状简介[J].中国冶金,2003(12):44～45
[7] Y.H.Xu, J.H.Peng,L.Fang. Nano-crystallization of steel wire and its wear behavior[J]. Materials Science and Engineering A. 2008 (483～484): 688～691
[8]李志深.钢丝生产工艺下册[M].湘潭:湘潭钢铁公司情报室,1992
[9]崔忠圻.金属学与热处理[M].北京:机械工业出版社,2000
[10] W.Van Raemdonck,I.Lefever,U.D Haene. Torsion Test as A Tool for High StrengthWire Evaluation[J].Wire Journal International.1994 (6):68～75
[11] A.Kagawa, T. Okamoto, H.Matsumoto. Young's Modulus and Thermal Expansion of Pure Iron-cementite Alloy Castings[J]. Acta Metallurgia.1987(4):797～803
[12]黄明志.GCr15钢不同回火态扭转流变硬化行为和组织强度研究[J].机械工程学报,1994,V30(5):94～99
[13] M.B. Chul, J.N. Won. Void Formation at Large Drawing Strain Pearlitic Steel wires. Wire Journal International[J].1997(7):102～105
[14]崔发明.高碳钢丝扭转断裂原因分析[J].金属制品2007,33(3):39～41
[15]王自森.拉拔时发热现象的探讨[J].金属制品,2005,11(4):14～16
[16]贺吉良.直接水冷拉丝模在钢丝生产中的应用[J].金属制品2001,27(5), 39～41
[17]邓世均.提高65Mn碳素弹簧钢丝扭转性能新工艺[J].四川冶金,2001 (4):39～41
[18]左伟,杨红燕.中碳钢丝热处理工艺及拉拔工艺对其性能的影响[J].金属材料,2005(6):83～87
[19]秦万信.钢丝的高速拉拔[J].金属制品,1990,25(2):28～31
[20] J.Gil Sevillano. Cleavage Limited Maximum Strength of Work-hardened B.C.C Polycristals[J].Acta Metallurgia.1986(34):1473～1485
[21]文一元.如何提高模具使用寿命[J].金属制品,1991,2l(l):15～19
[22]周健民,李建川.钢丝扭转试验的轴向拉力对其扭转次数的影响[J].物理测试,1992(4):50～53
[23] B.Goest, A. Martin-Meizoso,J.Gil-Sevillano. Fragmentation of As-draw Pearlitic Steel Wire During Torsion Tests [J]. Engineering Fracture Mechanics. 1998, 60(3): 255～272
[24] Y. Suzuki,M. Asakawa,H.Mizuno et al. Generating a mechanism of delamination in high carbon steel wire by experimental drawing[J].Wire Journal International,2005 (10):70～72
[25] J.K.Hallgarth. Torsion Ductility of High Carbon Steel Wire [J]. Iron making and Steel making.1995,22(3):211～222
[26] P. F. Willemse,B.P. Naughton,C.A.Verbraaka.X-ray residual stress measurements on cold-drawn steel wire[J].Materials Science and Engineering,1982(56):25～38.
[27] H.Overstam. The influence of bearing geometry on the residual stress state in cold drawn wire, analysed by the FEM[J].Materials Processing Technology,2006 (171):446～450
[28] D.K.Roberts, A.A.Wells. The Velocity of Brittle Fracture [J]. Engineering, 1984 (171):820～821
[29]何吉林.钢丝生产[M].北京:兵器工业出版社,2001
[30]崔约贤,王长利.金属断口分析[M].哈尔滨:哈尔滨工业大学出版社.1998
[31]汪守朴.金相分析基础[M].北京:机械工业出版社.1998
[32]张定锉,何家文.材料中残余应力的X射线衍射分析和作用[M].西安:西安交通大学出版社,1999
[33]赵敏,聂明芬,蔡磊.钢丝的扭转性能分析[J].金属制品,2007,33(6):34～36
[34]束德林.金属力学性能[M].北京:机械工业出版社,1999
[35]王世斌,亢一澜.材料力学[M].北京:高等教育出版社,2008
[36]黄明志.金属力学性能[M].西安:西安交通大学出版社,1986
[37]徐忠良.大跨度桥梁缆索用SWRS82B热轧盘条的组织与钢丝扭转性能研究[D].东南大学硕士论文,2006:20～35.
[38]弗里德曼.金属机械性能第一分册[M].北京:机械工业出版社,1982
[39]崔发明.高碳钢丝扭转断裂原因分析[J].金属制品,2007,33(3):39～41
[40]金属机械性能编写组.金属机械性能[M].北京:机械工业出版社,1986
[41]刘全坤.材料成形基本原理[M].北京:机械工业出版社,2005
[42] J.N.Won, M.B.Chul. Void initiation and micro-structural changes during wiredrawing of pearlitic steels[J].Materials Science and Engineering A, 1995 (203): 278～285
[43]鞍钢钢铁研究所,丘利,胡玉和.X射线衍射技术及设备[M].北京:冶金工业出版社,2003
[44]俞汉清,陈金德.金属塑性成形理论[M].北京:机械工业出版社,1999
[45]李亚智,赵美英,万小朋.有限元法基础与程序设计[M].北京:科学出版社,2004
[46]孟凡中.弹塑性有限变形理论和有限元方法[M].北京:清华大学出版社,1985
[47]冯果忱.非线性方程组迭代解法[M].上海:上海科学技术出版社,1989
[48]陈献廷.硬质合金使用手册[M].北京:冶金工业出版社,1986
[49] P.Gillstr?m, M. Jarl. Wear of die after drawing of pickled or reverse bent wire rod[J]. Wear. 2007 (262):858～867
[50] M.Elices. Influence of residual stresses in the performance of cold-drawn pearlitic wires [J].Materials science,2004 (39):3889～3899
[51]胡龙飞,刘全坤,王成勇等.基于多目标优化的钢管拉拔成形过程设计[J].农业机械学报,2007,38(10):161～164
[52]陈立周.机械优化设计方法[M].北京:冶金工业出版社,2005:12～25
[53]陈魁.试验设计与分析[M].北京:清华大学出版社,2005
[54]袁曾任.人工神经元网络及其应用[M].北京:清华大学出版社,1999
[55]徐敬,王秀坤,胡家升.基于神经网络的无源多传感器属性数据关联[J].系统仿真学报2003,15(1):127～131
[56] D.F. Cook, C.T. Ragsdale, R.L. Major. Combining a neural network with a genetic algorithm for process parameter optimization [J].Engineering Applications of Artificial Intelligence,2000, 13(4):391～396
[57]雷英杰,张善文,李续武等.MATLAB遗传算法工具箱及应用[M].西安:西安电子科技大学出版社,2005