Improvement of prediction model for work roll thermal contour in hot strip mill

Though high accuracy of the thermal contour was obtained while adopting finite element method,it could not meet the real-time requirement.One-dimensional finite difference method could realize real-time control in the case of neglecting both the circumferential and radical heat exchange,but the over-simplified modes resulted in poor accuracy.And two-dimensional full explicit difference was also limited in practical application since its time step was restricted to keep the model stable.Consequently,a new method of alternating direction finite difference was introduced and discussed in the model's stability,calculating speed and precision.Specific work roll after one real rolling unit was researched,The result shows that error of temperature on work roll surface between measured and calculated values is within 5 ℃.The influence of rolling rhythm and strip width on thermal crown was also studied.The conclusion is verified theoretically and practically that it can maintain absolutely stable and meet the online requirement.

Thermal Behaviors of Work Roll in Finishing Trains of Hot Rolling

In order to analyze the thermal field and thermal contour of work roll in finishing trains of hot rolling in rolling process, a quasi two-dimension implicit finite difference model is developed. To improve the calculating speed and precision, some special solutions are introduced, including the development of this model, the simplification of boundary conditions and the computation of heat transfer coefficients. The results show that these solutions of thermal behaviors of work roll are very much efficient and the model can be used as an on-line profile and fatness control model of large industrial mills.

Determination of Optimal Work Roll Profile for Cold Strip Mill

The model of predicting distribution of strip thickness at the exit and tension stress is established by using weighted residual method and variational method with consideration of rolled metal lateral flow.A New method of calculating loaded roll gap in relation to target tension stress is proposed.The minimum square summation of loaded roll gap deviation is used as an objective function for the first time to optimize initial work roll profile.

Improved model to solve influence coefficients of work roll deflection

According to the concept of virtual bending force,a rational explanation for SHOHET's model was presented. Considering the deformation characters of the work rolls in four-high mill,the deformation model of the work roll was regarded as a cantilever beam and new influence coefficients were deduced.The effect of the bending force was taken into account independently. Therefore,the contribution to work roll deflection caused by rolling load,rolling pressure between rolls and bending force can be got from the new formulas.To validate the accuracy of the formulas,the results obtained from the new formulas were compared with those from SHOHET's formulas.It is found that they highly coincide,which illustrates that the formulas are reliable.

Application of simulated annealing algorithm to improve work roll wear model in plate mills

Employing Simulated Annealing Algorithm (SAA) and many measured data, acalculation model of work roll wear was built in the 2 800 mm 4-high mill of Wuhan Iron and Steel(Group) Co. (WISCO). The model was a semi-theory practical formula. Its pattern and magnitude werestill hardly defined with classical optimization methods. But the problem could be resolved by SAA.It was pretty high precision to predict the values for the wear profiles of work roll in a rollingunit. After one-year application, the results show that the model is feasible in engineering, and itcan be applied to predict the wear profiles of work roll in other mills.

基于VB的Solid Works二次开发实例

阐述了以Solid Works为软件设计平台,利用VB对其进行二次开发.通过ActiveX Automation接口方式与VB的连接,可在Solid Works下自动创建圆锥滚子轴承零件模型.系统将帮助设计人员提高设计效率.

Solidworks在辊锻制坯中的应用

为适应三维辊锻模的设计要求,提出了基于三维中间毛坯模型的辊锻及模具设计方法,即通过构建辊锻件中间毛坯模型来进行变形量的计算和分配、确定型槽截面尺寸和纵向尺寸,并用Solidworks进行成功实现,提高了辊锻模具的设计质量和效率。

Roll shifting strategy with varying stroke and step in hot strip mill

A new roll shifting strategy with varying stroke and varying step was investigated,Two characteristic parameters including cat ear height and gap contour smoothness were introduced to assess the effect of shifting strategy on roll wear,and the relation between characteristic parameters and shifting strategy was established.Both varying stroke and varying step can reduce cat ear height and gap contour smoothness,so the shifting strategy with varying stroke and varying step is better than the one with either varying stroke or varying step,Based on the effect of shifting control parameters on characteristic parameters of roll wear,the selection principle of these shifting control parameters was gained.A case study was conducted to validate the proposed roll shifting strategy,reducing uncontrollable quartic loading gap contour,improving strip profile and extending rolling length of a rolling campaign.

Wear and Thermal Stress Analysis of Side Dam for Twin Roll Strip Casting

The simulation of the work roll temperature field was carried out by means of ANSYS software, and the thermal crown of the roll along its axis was obtained. The thermal-structural coupled element and contact element were introduced. In the simulation of work roll temperature field, the convert boundary condition and the transient thermal contact between the roll and strip were studied. Besides, the dynamic variation of the work roll temperature and the transient temperature distribution of the work roll during hot rolling were investigated. The calculated results were in good agreement with the measured data.

Accu Roll轧管机的空间解析及运动学分析

通过对Ａｃｃｕ Ｒｏｌｌ轧管机空间结构的分析，提出了计算工艺参数和速度参数的数学模型，并结合生产实际进行了分析。该模型对辊型的设计及轧制工艺参数的计算提供了依据。

基于脉冲涡流监测与Wiener过程的再制造工作辊实时剩余寿命预测方法

再制造工作辊在热轧工作过程中熔覆层易发生复杂的退化行为,而其性能退化会影响轧制产品的质量。为实时监测轧辊退化情况并预测其剩余寿命,构建一套在线脉冲涡流监测方法和系统,采用变分模态分解-希尔伯特变换(VMD-Hilbert)方法提取0~5000 Hz频率边际谱能量和的增量作为轧辊退化特征。基于此,构造考虑个体差异的状态退化空间模型,结合最大期望(EM)算法和Kalman平滑滤波算法联合对模型中未知参数进行自适应参数估计,并利用层次分析法融合监测的历史数据与实时数据,以实现对再制造工作辊实时剩余寿命预测。实验结果表明,所提方法能够准确预测再制造工作辊剩余寿命,具有一定的应用前景。

ANISOTROPY OF WORK HARDENING IN 5456 ALUMINUM ALLOY

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Investigation into microstructure of spray formed V4 cold working mould steel and its roiling and annealing

The material selected for this work was the spray formed Vanadis4 high alloy cold working mould steel （abbreviated to V4 steel）. Its microstructure, hot rolling process, and annealing treatment have been investigated. Observed from the optical and electron microscopes, the as-sprayed V4 steel had the finer microstructure of uniform and equiaxial grains ,while after hot rolling for densification and spheroidized annealing, the V4 steel obtained an excellent spheroidized structure that is favorable to subsequent quenching and tempering treatment. The spheroidized structure and level of annealed hardness of the V4 steel are almost the same as expensive imported powder metallurgy the V4 steel. It is difficult to produce V4 steel with the conventional ingot metallurgical technique, so the multi-step and high-cost powder metallurgy method is generally used at present. Compared to the powder metallurgy technique, using the spray forming technique to produce the V4 steel has obvious advantages and potential market competitiveness in reducing production costs, simplifying working process, and shortening the production cycle.

Effect of cold rolling on the microstructural, magnetic, mechanical, and corrosion properties of AISI 316L austenitic stainless steel

This study has evaluated the effect of different levels of cold rolling（from 0 to 50%）on the microstructural,magnetic,and mechanical properties and the corrosion behavior of 316L austenitic stainless steel in Na Cl（1 mol/L）＋H_2SO_4（0.5 mol/L）solution.Microstructural examinations using optical microscopy revealed the development of a morphological texture from coaxial to elongated grains during the cold-rolling process.Phase analysis carried out on the basis of X-ray diffraction confirmed the formation of the ferromagneticα′-martensite phase under the stresses applied during cold rolling.This finding is in agreement with magnetic measurements using a vibrating sample magnetometer.Mechanical properties determined by tensile and Vickers microhardness tests demonstrated an upward trend in the hardness-to-yield strength ratio with increasing cold-rolling percentage,representing a reduction in the material’s work-hardening ability.Uniform and localized corrosion parameters were estimated via potentiodynamic polarization corrosion tests and electrochemical impedance spectroscopy.In contrast to the uniform corrosion,wherein the corrosion current density increased with increasing cold-working degree because of the high density of microstructural defects,the passive potential range and breakdown potential increased by cold working,showing greater resistance to pit nucleation.Although pits were formed,the cold-rolled material repassivation tendency decreased because of the broader hysteresis anodic loop,as confirmed experimentally by observation of the microscopic features after electrochemical cyclic polarization evaluations.

宽板连轧锥形工作辊轴向窜动调控及工业应用

为了提高连轧锥形工作辊轴向窜动控制精度,对材料加工时发生横向流动的过程建立有限元模型,并构建了机架轧后屈服模型,并将模型置于现场环境中开展验证研究。研究结果表明:受到轧后屈服作用时,处于边降区(15~115)mm之间的断面误差可以控制到3μm范围内,与带钢边部的最大偏差在(0~15)mm之间。在机架间和轧制区内都出现了横向流动的情况,导致锥形辊发生了边降调控性能下降。随着窜辊量增大后,第一、二机架都出现功效下降的结果,第三机架则持续增大至最高功效。下游机架窜辊位都位于上游机架控制特征点范围内。这里调控方式形成了显著边部效果,可以观察到内部偏差。该研究对保证板材的轧制质量具有很好的实际指导价值。

基于卷积神经网络的多工况多传感滚动轴承实时监控方法

针对工业环境中广泛在多工况下多滚动轴承实时状态监测的需求和部署环境受限的挑战,提出一种基于卷积神经网络(Convolutional Neural Network,CNN)的面向多传感器滚动轴承运行状态监控方法。该方法将两个不同工况下的一维时间序列数据集以均方根(Root Mean Square,RMS)指标标注,并通过将一维时间序列多传感器数据重构为二维空间张量的形式输入卷积神经网络训练。最后利用层融合和16比特量化优化,将网络部署到FPGA上,用以解决CNN的计算开销。实验结果表明,在结合了两种不同工况的数据集下,网络测试推理准确度依然高达99.24%,比多层感知机实现高10.48%,比多层感知机结合支持向量机的实现高2.91%,该算法对于新加入的数据集也有较强的鲁棒性,经过重训练,新加入的数据集准确率可以达到99.17%。基于FPGA部署优化的网络的峰值能效为76.217GPOS/W,为CPU实现的33.09倍,GPU实现的5.39倍。其中,16比特精度部署的网络测试精度相较32比特精度实现仅降低0.001%。

四工作辊轧机轧制304不锈钢板件截面塑性变形分析

针对四工作辊轧机轧制304不锈钢板件存在变形量大、尺寸不稳定的问题,利用Solidworks软件建立四工作辊轧制系统有限元模型,采用Deform软件对304不锈钢板件在不同轧辊直径、轧辊转速和轧辊压下量下进行轧制仿真,分析其对轧件截面高度和等效应力分布的影响,根据轧制仿真分析结果设计制造了四工作辊轧机,并对不同压下量下仿真和生产的轧件截面高度进行对比分析。结果表明,轧件截面塑性变形可分为相互作用Ⅰ区、过渡Ⅱ区和变形Ⅲ区,等效应力、等效应变和截面高度在Ⅰ区最大,在Ⅲ区最小且变化平稳,Ⅱ区值位于两者之间并呈U型分布。

超声滚压对DC53钢表面性能的影响

为了改善DC53冷作模具钢的表面性能,使用扫描电子显微镜、激光光谱共聚焦显微镜、显微硬度计、球-盘摩擦磨损试验机等设备分析了超声表面滚压加工工艺(USRP)的静压力、滚压道次、振幅、进给量对DC53冷作模具钢表面粗糙度、显微硬度、摩擦因数和磨损的影响规律。结果表明:与未处理DC53模具钢相比,USRP处理后DC53冷作模具钢表面产生了塑性变形,表面粗糙度由5.570μm最低可降为1.067μm,且在DC53冷作模具钢表面产生了晶粒细化现象,引入了梯度硬化层,表面硬度由基体的720 HV最大可提升为818.6 HV,硬化层深度最大可达300μm。摩擦因数降低,磨痕宽度减小,耐磨性能提高。通过极差分析法获得了对粗糙度、显微硬度、摩擦因数影响最大的工艺参数依次为进给量、滚压道次、静压力。通过灰色关联度分析法获得了工艺参数对表面性能的影响次序为静压力>进给量>滚压道次>振幅,最佳工艺参数组合为静压力400 N,滚压道次4次,振幅12μm,进给量0.05 mm。

四辊轧机工作辊辊颈端部铸接修复部位寿命评估

轧辊作为带钢生产轧机的核心部件,其消耗对生产成本有重要影响。随着钢铁企业竞争加剧导致的降本增效需求逐步提高,轧辊再制造循环利用得到逐步推广。大型轧机大尺寸轧辊工作层消耗后改造用于小轧机为其中主要方式之一;对于局部尺寸尤其是辊肩尺寸不足的轧辊通常采用铸接方式加长以满足进一步使用的需求;铸接再制造后轧辊的使用寿命成为保障安全生产的关键。针对上述问题,在轧辊铸接部位取样开展了疲劳性能测试,同时选用扭转疲劳模型在证明计算精度的基础上,结合基于现场生产数据建立的载荷谱,对工作辊修复后的辊颈进行了寿命预测,预期服役寿命满足现场对修复后轧辊的性能需求,可为现场轧辊安全使用维护制度建立提供理论支撑。

一种海洋自升式修井平台船型分析

针对渤海海域油气开发中自升式修井平台的船型设计,进行系统分析。从桩腿数量维度出发,考虑波流载荷、风载荷和平台重力的共同作用,通过有限元数值模拟软件,建立自升式修井平台的仿真模型,计算不同方向角下平台的波流载荷、桩腿位移和抗倾力矩等评价指标,综合对比分析三桩腿和四桩腿两种不同船型的设计特点,以揭示各自在平台方案、预压载能力和稳定性等方面的特点。研究结果发现,四桩腿平台在舱内设备布置、预压载能力和抗倾稳性方面具有明显优势,特别是在单桩失效情况下,四桩腿平台的稳定性和安全性更高。研究结论对自升式修井平台的设计优化具有重要的指导意义,为进一步提升平台的安全性和高效性提供理论依据。