中空钢轧制过程数值模拟及尺寸精度分析
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摘要
钎杆用中空钢,简称“钎钢”。目前国内生产钎钢的方法主要是钻孔法,与热穿-热拔的方法相比较,钻孔法生产的中空钢最大优点是产品冶金质量好,使用寿命较高,因此具有广阔的发展前景。但实际生产中出现偏心和椭圆度等问题有待解决。
关于钎杆用中空钢的研究,以前多集中在钎杆使用过程中应力、应变状态分析、寿命评估、热处理工艺、选材方面,而对钎杆用中空钢轧制过程的研究很少,且都是采用实验和定性分析的方法,从开坯到精轧,轧制工艺参数对轧件的变形的影响规律研究更是处于初级阶段。
利用Gleeble-3500热/力模拟试验机进行热模拟试验,采用单道次压缩试验的方法,研究了芯棒用高锰钢80Mn14在钻孔法生产钎钢的轧制工艺范围内的高温变形力学行为。并得出了高锰钢80Mn14的高温流变应力数学模型。为有限元数值模拟材料库的建立奠定基础。
首先调查了钎杆用中空钢的国内外研究状况,简单介绍了国内钎钢的基本要求以及生产钎钢的主要生产工艺概况。系统地阐述了刚塑性有限元的基本理论。利用Pro-E软件建立了三维模型,以DEFORM-3D有限元分析软件为平台,对钻孔法生产钎钢从开坯到精轧二十个道次轧制过程进行了数值模拟。直观清晰地观察到了各道次轧件的不均匀变形和畸变过程,得出了各道次中轧件的轧制力、轧制力矩、轧件的温度场、等效应力的分布、金属流动的速度场以及轧件的形状,分析了轧制过程中各个孔型变形区的金属流动规律。对现有设计孔型进行了数值模拟,指出了设计孔型在轧制过程中存在的问题,对优化设计工艺和完善技改方案有着重要的现实意义。根据模拟的结果,进行尺寸精度分析以及实际生产钎钢中产生偏心的原因,并对孔型系统进行改进。
Hollow drill steels which act as drilling steel rods are named rock drill steels for short. Nowadays, the drilling method is the main method of processing rock drill steels in our country. In comparison with the hot piercing and hot stretching method, the drilling method is more promising, because the products’metallurgical quality in the drilling method is better which is the best advantage, and their finished products’life-span is longer. However, the eccentricity and the ellipse degress of actual production appears to be resolved such issues.
In the past, research about hollow drill steels which act as drilling steel rods were mainly converged in strain and stress in work、life-span estimate、hot treatment technology as well as the choice of material. Few people researched rock drill steels about the process of rolling and they often adopted experimental or qualitative methods. Form cogging to rolling, the research on the influence law of the deformation of the rolled piece is still in its initial stage.
Using Gleeble-3500 thermal-mechanical testing machine thermal simulation experiment, using single-pass compression test method to study the mandrel in the borehole with high manganese steel 80Mn14 the production of drill steel rolling process thermal deformation within the behavior. And reached a high manganese steel 80Mn14 high temperature flow stress model. The establishment of the model lays a foundation for establishing library materials.
First investigated the use of hollow steel rod at home and abroad of the situation, briefly introduced the basic requirements of domestic drill steel and the production of the main drill steel production process overview. Expounds systematically the basic theory of rigid-plastic FEM. Using Pro-E software to build a three-dimensional model to DEFORM-3D finite element analysis software for the platform, the production of drill steel drill blanks to roll from the cogging to rolling 20 pass process was simulated. Clearly observed visually each pass rolling process of uneven deformation and distortion, each pass is obtained in the rolling of the rolling force, rolling moment, rolling temperature field, the distribution of equivalent stress, metal flow The velocity field and the rolling shape of the rolling deformation zone during each pass of the metal flow law. Pair of existing designs pass the numerical simulation indicates the design pass during the rolling process problems, optimizing the design of the process and perfect technological transformation has important practical significance plan. According to the simulation results, for dimensional accuracy analysis, and generate the actual production of drill steel eccentric reasons, and the pass system to improve it.
关于钎杆用中空钢的研究,以前多集中在钎杆使用过程中应力、应变状态分析、寿命评估、热处理工艺、选材方面,而对钎杆用中空钢轧制过程的研究很少,且都是采用实验和定性分析的方法,从开坯到精轧,轧制工艺参数对轧件的变形的影响规律研究更是处于初级阶段。
利用Gleeble-3500热/力模拟试验机进行热模拟试验,采用单道次压缩试验的方法,研究了芯棒用高锰钢80Mn14在钻孔法生产钎钢的轧制工艺范围内的高温变形力学行为。并得出了高锰钢80Mn14的高温流变应力数学模型。为有限元数值模拟材料库的建立奠定基础。
首先调查了钎杆用中空钢的国内外研究状况,简单介绍了国内钎钢的基本要求以及生产钎钢的主要生产工艺概况。系统地阐述了刚塑性有限元的基本理论。利用Pro-E软件建立了三维模型,以DEFORM-3D有限元分析软件为平台,对钻孔法生产钎钢从开坯到精轧二十个道次轧制过程进行了数值模拟。直观清晰地观察到了各道次轧件的不均匀变形和畸变过程,得出了各道次中轧件的轧制力、轧制力矩、轧件的温度场、等效应力的分布、金属流动的速度场以及轧件的形状,分析了轧制过程中各个孔型变形区的金属流动规律。对现有设计孔型进行了数值模拟,指出了设计孔型在轧制过程中存在的问题,对优化设计工艺和完善技改方案有着重要的现实意义。根据模拟的结果,进行尺寸精度分析以及实际生产钎钢中产生偏心的原因,并对孔型系统进行改进。
Hollow drill steels which act as drilling steel rods are named rock drill steels for short. Nowadays, the drilling method is the main method of processing rock drill steels in our country. In comparison with the hot piercing and hot stretching method, the drilling method is more promising, because the products’metallurgical quality in the drilling method is better which is the best advantage, and their finished products’life-span is longer. However, the eccentricity and the ellipse degress of actual production appears to be resolved such issues.
In the past, research about hollow drill steels which act as drilling steel rods were mainly converged in strain and stress in work、life-span estimate、hot treatment technology as well as the choice of material. Few people researched rock drill steels about the process of rolling and they often adopted experimental or qualitative methods. Form cogging to rolling, the research on the influence law of the deformation of the rolled piece is still in its initial stage.
Using Gleeble-3500 thermal-mechanical testing machine thermal simulation experiment, using single-pass compression test method to study the mandrel in the borehole with high manganese steel 80Mn14 the production of drill steel rolling process thermal deformation within the behavior. And reached a high manganese steel 80Mn14 high temperature flow stress model. The establishment of the model lays a foundation for establishing library materials.
First investigated the use of hollow steel rod at home and abroad of the situation, briefly introduced the basic requirements of domestic drill steel and the production of the main drill steel production process overview. Expounds systematically the basic theory of rigid-plastic FEM. Using Pro-E software to build a three-dimensional model to DEFORM-3D finite element analysis software for the platform, the production of drill steel drill blanks to roll from the cogging to rolling 20 pass process was simulated. Clearly observed visually each pass rolling process of uneven deformation and distortion, each pass is obtained in the rolling of the rolling force, rolling moment, rolling temperature field, the distribution of equivalent stress, metal flow The velocity field and the rolling shape of the rolling deformation zone during each pass of the metal flow law. Pair of existing designs pass the numerical simulation indicates the design pass during the rolling process problems, optimizing the design of the process and perfect technological transformation has important practical significance plan. According to the simulation results, for dimensional accuracy analysis, and generate the actual production of drill steel eccentric reasons, and the pass system to improve it.
引文
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16 U Beste,E. Coronel and S. Jacobson.Wear induced material modifications of cemented carbide rock drill buttons. International Journal of Refractory Metals and Hard Materials,2006,24(01):168~176
17 Thomas Svensson. Fatigue life prediction based on variable amplitude tests-specific applications. International Journal of Fatigue, 2005,27(08):966~973
18贺建国.我国小钎杆的质量问题及其原因分析.矿业研究与开发,2000,20(5):48-50
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29饶建华,张国榉.中空钢轧制工艺对H22-40SiMnCrNiMo钎杆寿命影响研究.矿山机械, 2001,(12):16-17
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2王元辉,程巨强,刘志学.国内外常用钎头用钢的新发展.凿岩机械气动工具,2004,(04):32-33
3董鑫业,胡铭.国内外钎钢与钎具.凿岩机械气动工具, 2007,(01):1-5
4徐曙光.我国钎钢钎具的发展与进步.特殊钢, 1990,(05):18-21
5董鑫业,胡铭.我国凿岩钎具行业的发展.特殊钢, 2006,(04):1-7
6刘世华.用局部应力-应力法估算钎杆寿命.凿岩机械气动工具, 2000,(1):24-26
7赵统武.钎杆的工作载荷谱和疲劳寿命估测.钢铁, 1983,18 (7):11-14
8叶凌云,李宗安.重型钎杆的工艺探索及选材.凿岩机械气动工具, 1999,(3):46-48
9黎炳雄.螺纹钎杆的失效分析和断裂机理.凿岩机械气动工具, 1999,(2):55-60
10宋守志,吕荣,唐春安.凿岩机理理论载荷谱与钎杆抗疲劳性能的动力响应.东北大学学报, 1996,17(06):579-584
11宋守志,钟勇.矿产资源综合利用现状与发展的研究.金属矿山,2006,(11):234-236
12张国榉,刘湘荣,陈泓.凿岩钎具的设计、制造和选用.长沙:湖南科学技术出版社, 1998:25-26
13 New land D E. An Introduce to Random Vibration and Special Analysis. Edinburgh: Longm an Group Ltd,1975:42~155
14单仁亮.石板冲击凿入的变形与破坏规律.中国矿业大学学报, 2005,(05):40-45
15 Tezcan Sekercioglu. Failure study of pneumatic rock drill piston. Engineering Failure Analysis,2006,13(07):1108~1115
16 U Beste,E. Coronel and S. Jacobson.Wear induced material modifications of cemented carbide rock drill buttons. International Journal of Refractory Metals and Hard Materials,2006,24(01):168~176
17 Thomas Svensson. Fatigue life prediction based on variable amplitude tests-specific applications. International Journal of Fatigue, 2005,27(08):966~973
18贺建国.我国小钎杆的质量问题及其原因分析.矿业研究与开发,2000,20(5):48-50
19马庆云.大比重泥浆超声测距的研究. [山东矿业学院工学硕士论文].1994:23-26
20张国榉.长寿命冲击凿岩钎杆.凿岩机械气动工具, 1999,(4):21-25
21刘广志.中国钻探技术史.北京:地质出版社, 1998:90-95
22张国榉,张汉斌.硬质合金复合片齿钎具.武汉:中国地质大学出版社, 1997:74-77
23张国榉,何小林,张汉斌,等.复合钎头暨新型钎杆显现强劲生命力.凿岩机械气动工具, 2004,(03):6-11
24常宏振.液压破碎钎杆的合理使用.工程机械与维修, 2005,(04):149
25高理福,宋霖.气动凿岩机钎杆噪声的控制.凿岩机械气动工具, 2005,(03):17-21
26钟勇,邢军,宋守志.钎杆结构与抗疲劳寿命研究.中国矿业, 2005,(12):78-81
27郑光海,李学伟,孙俭峰.ZK55SiMnMo钎杆早期失效分析及工艺改进.吉林林业科技, 2004,(04):44-45
28叶凌云,冯志勇.凿岩钎杆用中空钢热穿-热轧法生产工艺介绍.凿岩机械气动工具,2008, (02)42-49
29饶建华,张国榉.中空钢轧制工艺对H22-40SiMnCrNiMo钎杆寿命影响研究.矿山机械, 2001,(12):16-17
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