Effect of sizes of forming rolls on cold ring rolling by 3D-FE numerical simulation

During cold ring rolling process, changing the sizes of forming rolls including driver roll and idle roll will lead to a change of amount of feed Ah and contact areas between ring blank and forming rolls, thus a change of the shape and dimension of deformation zone located in the gap of forming rolls is found. It has a significant effect on metal flow and the forming quality of deformed ring. So the size effect of forming rolls on cold ring rolling was investigated by three-dimensional dynamic explicit FEM under ABAQUS environment. The obtained results thoroughly reveal the influence laws of the sizes of forming rolls on the average spread, fishtail coefficient, degree of inhomogeneous deformation and force and power parameters etc not only provide an important basis for design of the forming rolls and optimization of cold ring rolling process, but also reveal the plastic deformation mechanism of cold ring rolling.

Rolling Fatigue Test of Large-Sized UHPC Member for Cable Stayed Bridge

Recently, research strives to apply Ultra High Performance Concrete (UHPC) to large-sized structures owing to its remarkable mechanical performance and durability compared to normal concrete. The Korea Institute of Construction Technology proposed SuperBridge800, an edge girder type UHPC cable stayed bridge with central span of 800 m, through its detailed design. The bridge is designed to be erected through the connection of precast UHPC segments. The precast UHPC segment is monolithically composed of one ribbed deck slab and edge girders at each side. The connection between the precast segments is achieved by steel bars at the edge girders and by UHPC cast-in-place wet joint at the slab. Despite of the outstanding mechanical performance of UHPC, the fabrication of large-sized members is a difficult task since UHPC hardens faster than normal concrete and requires a special curing process. Therefore, the constructability of large-sized UHPC segment should be secured to achieve SuperBridge800. Besides, the performance of the connection between segments should also be guaranteed, especially in terms of the fatigue performance of the UHPC cast-in-place joint, which constitutes a weak point. To that goal, two half-scaled UHPC segments are manufactured and the constructability is examined by fabricating a large-sized UHPC member connected with respect to the design conditions. This study conducts rolling fatigue test on the so-fabricated large-sized UHPC member. Rolling fatigue test is carried out up to 2 million cycles considering actual vehicle load at each center and quarter points of the member. The test results confirm that the service limit state is satisfied.

A NEURAL NETWORK-BASED MODEL FOR PREDICTION OF HOT-ROLLED AUSTENITE GRAIN SIZE AND FLOW STRESS IN MICROALLOY STEEL

For the great significance of the prediction of control parameters selected for hot-rolling and the evaluation of hot-rolling quality for the analysis of prod uction problems and production management, the selection of hot-rolling control parameters was studied for microalloy steel by following the neural network principle. An experimental scheme was first worked out for acquisition of sample data, in which a gleeble-1500 thermal simolator was used to obtain rolling temperature, strain, stain rate, and stress-strain curves. And consequently the aust enite grain sizes was obtained through microscopic observation. The experimental data was then processed through regression. By using the training network of BP algorithm, the mapping relationship between the hotrooling control parameters (rolling temperature, stain, and strain rate) and the microstructural paramete rs (austenite grain in size and flow stress) of microalloy steel was function appro ached for the establishment of a neural network-based model of the austeuite grain size and flow stress of microalloy steel. From the results of estimation made with the neural network based model, the hot-rolling control parameters can be effectively predicted.

Fe-3%Si平面流铸带平整轧制退火过程中组织织构演变

采用平面流铸技术制备了Fe-3%Si无取向硅钢极薄带,研究了平面流铸Fe-3%Si薄带平整轧制与退火处理的组织织构演变规律。结果表明,平面流铸带具有大比率的柱状晶组织,{100}取向晶粒占比高于30%,也即存在对磁性能有益的{100}织构。小压下率冷轧平整过程中,晶粒取向变化及晶内取向分裂程度整体不高,形变行为存在取向依赖性。{100}取向晶粒形变储能积累程度相对较低,经退火处理后该组分体现出遗传优势,在退火组织中占比仍超过30%。退火组织中小尺寸晶粒有所增加,且绝大部分小尺寸晶粒偏离{100}取向,这导致了退火组织平均晶粒尺寸降低,并在一定程度上弱化{100}织构。

退火温度对GH3600合金箔材组织与性能的影响

目的探究退火温度对GH3600镍基高温合金箔材微观组织及力学性能的影响。为制备综合性能良好的GH3600箔材提供参考。方法将厚度为2 mm的铸态板材反复轧制退火得到组织均匀的0.3 mm厚度带材,再利用四辊冷轧机将带材轧制成厚度为0.1 mm和0.05 mm的箔材,然后将2种厚度箔材在950、1000、1050℃下保温1 h后空冷。通过金相观察、电子探针、EBSD检测及XRD分析来研究箔材的微观组织演变。通过拉伸实验检测箔材的室温拉伸性能。结果随着变形程度的增大,轧制态箔材晶粒沿轧制方向被拉长得更加明显。在相同热处理参数下,0.05 mm退火态箔材晶粒尺寸更小。退火后,箔材晶粒发生了回复再结晶并析出了细小的碳化物。随着退火温度的升高,晶内碳化物逐渐减少,孪晶界比例增大,再结晶程度及晶粒尺寸增大。0.05 mm箔材在1050℃退火时,其晶粒迅速粗化,在厚度方向上出现单层晶,导致箔材的抗拉强度及延伸率出现异常降低的现象,即“越小越弱”的尺寸效应。结论适宜的热处理工艺有助于改善箔材的微观组织,进而提高其力学性能。0.05 mm箔材在950℃下退火1 h时,其延伸率为19.1%,屈服强度以及抗拉强度分别达到293 MPa和560 MPa,综合力学性能良好。

压延率对无氧铜板高温退火的组织及性能影响

高导热AMB陶瓷基板的覆铜厚板性能直接影响基板的电性能和力学性能。通过对无氧铜原料板的加工、微观组织调整以及陶瓷与铜板的活性焊料复合,达到AMB陶瓷覆铜基板最优的组织状态和电学与力学性能。首先对无氧铜板原料进行450℃和650℃再结晶退火0.5 h处理,得到两种原始的铜板组织。其次,对原始铜板进行压延率为15%、30%、45%、60%、75%的压延和800℃/1 h的退火处理,研究了退火铜板的微观组织及力学性能和电学性能。结果表明:当压延率在15%~75%时,随着压延率增加,晶粒逐渐被拉长变成扁平状,再变成纤维状;硬度随着压延率增加逐渐增大,铜板的延伸率逐渐减小,抗拉强度在压延率为15%~60%时逐渐增大,压延率达到75%时出现了小幅度降低。当在800℃退火1 h后,铜板表面晶粒尺寸随着压延率的增加逐渐减小,晶粒分布更加均匀,其大小稳定在400~800μm之间。铜板在压延率为15%~60%时的抗拉强度基本保持不变;当压延率到达75%时,抗拉强度出现小幅度降低。铜板硬度随着压延率增加基本保持不变。当压延率从15%变为75%时,铜板的电阻率有小幅度上升。

肿瘤射频消融技术及临床应用研究进展

目的该研究旨在探讨射频消融在大尺寸肿瘤中存在的技术难题及解决方法,以提高射频消融技术在临床治疗中的应用效果。方法该研究基于射频消融的原理,分析“降滚”现象对大尺寸肿瘤完全消融的限制,并探讨大血管散热引起的消融不完全问题,从而引出在射频消融中应用数学建模仿真来判断消融损伤程度的方法。结果和结论该研究基于相关研究现状,强调数学建模仿真在射频消融中的作用,即术前模拟以预测消融效果,指导临床优化治疗方案以提高治疗效果。创新之处该研究总结了优化消融器械设计、模拟仿真等措施以改进治疗效果,并展望了射频消融技术的发展方向,如引入肿瘤联合治疗和智能化技术,以提高射频消融的精准性和完全性。

舰载战斗机增阻轮挡几何尺寸设计方法

在进行舰载战斗机的起降性能试飞或舰载机飞行员训练时,通常需要使用止动轮挡。然而,止动轮挡的结构复杂、占用大量空间且成本昂贵。为应对舰载机在陆基试飞和飞行员训练中的需求,提出一项创新性的解决方案,即采用成本更为经济的增阻轮挡来替代止动轮挡。基于经典动力学理论,建立舰载机和增阻轮挡之间的数学模型。以某型舰载机为例,进行详细的定量分析,探讨舰载机的重量及增阻轮挡的倾斜角度对舰载机在增阻滑行中的影响。研究结果显示,适用的增阻轮挡倾斜角度取决于舰载机的发动机推力和起飞重量范围。对于某型舰载机,在最小起飞重量G0到最大起飞重量G0+12000 kg之间,适用的增阻轮挡倾斜角度范围为14~21°。因此,在进行舰载机的陆基飞行试验或飞行员训练时,可以选择倾斜角度为17.5°,高度为46.3 mm,宽度为机轮宽度的2~3倍的增阻轮挡。此外,研究结果还指出,舰载机的起飞重量包线越宽,适用的增阻轮挡倾斜角度范围就越狭窄。该研究为提高经济性和效率性提供一种替代止动轮挡的方法,有望在舰载机试验和训练中得到广泛应用。

晶粒尺寸对竹节晶铜箔微轧制变形行为影响的模拟

高性能铜箔已经广泛应用于新能源、微电子等领域,为降低其制备成本和调控组织性能,对拉拔−压缩−剪切复合成形条件下的竹节晶铜箔轧制微观变形行为进行研究。建立微观尺度的晶体塑性有限元模型,分析竹节晶微轧制变形的晶粒尺寸效应。该微观模型将每个离散单元只是作为晶粒的组成部分,同时在积分点上采用单晶体本构模型建立本构方程。结果表明:微观层次复合轧制竹节晶铜箔的变形特征表现为高度的异向性和局部化;竹节晶铜箔轧制力变化符合类似Hall-Petch关系,即轧制力随晶粒尺寸的减小而增大;随着晶粒尺寸减小,复合轧制竹节晶铜箔的滑移均匀性和晶界滑移协调能力均增强;动态剪切带和变形带随着晶粒尺寸的减小向晶界偏移。为保证轧制竹节晶铜箔变形的稳定性和进一步减薄,晶粒尺寸小于100μm为宜。

旋转速度对滚动摩擦沉积增材组织的影响

滚动摩擦沉积增材(Additive Friction Rolling Deposition,AFRD)是一种新兴的金属固态增材制造技术,特别适用于基于熔合增材制造方法易产生凝固缺陷的高强度铝合金。采用AFRD方法进行2024-O铝合金增材,获得全致密无缺陷的四层增材试件,利用金相显微镜、扫描电子显微镜对不同旋转速度增材试件宏观形貌、微观组织进行了表征。结果表明:(1)沉积层组织致密,无夹杂、裂纹等缺陷、相邻两沉积层之间形成良好的冶金结合。(2)沉积层呈现细小的轴晶粒组织,随着旋转速度升高,晶粒尺寸呈下降趋势。(3)沉积层第二相粒子呈现点片状分布于Al基体上,随着转速增大,第二相粒子趋向于细化与均匀。

基于最大均值差异的卷积神经网络故障诊断模型

针对工程场景中轴承故障数据采集困难,小样本下轴承故障诊断准确率较低且稳定性不高的问题,提出了一种小样本下滚动轴承故障的诊断方法,即基于最大均值差异(MMD)的卷积神经网络(CNN)诊断模型(方法)。首先,根据轴承故障机理,获取了滚动轴承故障的仿真信号,基于生成式对抗网络构建了仿真信号与少量真实样本间的对抗训练模型,得到了伪域样本,并将其扩充为训练数据集;其次,以交叉熵损失和最大均值差异(MMD)为卷积神经网络(CNN)的优化准则,引入了缩放因子,对网络进行了动态优化,根据测试结果选取缩放因子为0.05作为最优网络结构参数,构建了故障诊断的训练模型;最后,将结构均为1024个数据点的伪域样本和真实样本共同构成模型的训练集,对其进行了归一化处理,然后将其输入到构建的网络模型中,并以MMD作为约束,进行了卷积、池化操作,以实现特征提取的目的,经反向传播对模型进行了优化,实现了诊断模型参数的迭代更新目标。研究结果表明:基于MMD的CNN诊断模型(方法)对小样本下轴承的故障诊断识别精度有明显的改善,当样本数仅为16时,识别率可达95%以上,证明该方法在小样本下的轴承故障诊断中依然能获得较高的故障识别率。

齿辊破碎机产品粒度图像边缘检测算法的实验分析研究

产品粒度是齿辊破碎机的一个重要运行指标,其优劣直接关系整套生产系统运行的经济效益。精准、快捷的产品粒度检测方法能够为调整齿辊破碎机各项参数提供有效指导,提高生产系统的运行效率,实现矿产资源利用最大化。产品粒度图像边缘检测是利用计算机检测粒度的关键环节,以齿辊破碎机破碎后的石灰石产品为研究对象,对比Roberts、Prewitt、Sobel、Canny几种算子的检测结果,为后续齿辊破碎机产品粒度检测方法优选提供参考。

高压辊磨技术在铜冶炼渣粉磨工艺中的应用研究

对铜冶炼渣进行了高压辊磨开路试验、边料循环试验、闭路粉磨试验以及与颚式破碎机产品的磨矿对比实验,并对各产品进行了粒度分析。结果表明,铜冶炼渣经高压辊磨处理后,产品中细粒级含量明显增加,可磨度提高约36个百分点,高压辊磨有利于提高铜冶炼渣的磨矿效率和选矿技术指标。

超导用铌板的轧制工艺研究

金属铌是超导线材重要的阻隔层材料,铌板通过卷筒焊接后,装入Nb3Sn、NbTi等超导芯部材料,经过挤压、集束拉拔等工序得到超导线材。铌板在加工过程中经过多道次变形、多次退火,最终以超导线材阻隔层的形式存在。因此,对超导线材用铌板的晶粒度、力学性能及均匀性等方面提出较高要求。对铌板的轧制工艺、热处理制度设计了对照试验并进行了深入研究。通过对比成品板材的晶粒度、力学性能差异,分析并得到了最优方案。开坯锻造、热轧、中间轧制以及成品轧制温度分别为1300℃、1050℃、960℃以及860℃工艺下,所生产的超导用铌板晶粒度为≥5.0级(以6.0~7.0级为佳)、再结晶率≥95%、Rp0.2≥72MPa,其再结晶率与屈服强度合格率较高,晶粒度分布均匀且评级合格。在稳定生产工艺与产品质量的基础上,对比总结的铌板轧制工艺对提高产品质量、积累超导铌材加工经验具有重要意义。

将军戈壁二矿2PLF100/300分级破碎机破碎工艺优化

针对将军戈壁二矿露天破碎站2PLF100/300分级破碎机调试期间出现的齿辊卡堵、电流保护、30~80 mm煤块产品粒度超限等问题,通过调节上下游设备联锁关系、调整齿辊间距、增设溜槽布料装置,使破碎系统工艺得到优化,同时延长了破碎齿板使用寿命,降低了30~80 mm煤块产品粒度超限率,提高了整体运行效率。

直接轧制中连铸坯输送节奏衔接的优化

通过运筹学中的排队理论,建立了方坯直轧系统中连铸坯排队模型,并对唐钢公司长材事业部方坯-棒材直轧系统分析优化,为企业生产管理提供理论依据。结果显示,当连铸机拉速为3.8 m/min,连铸坯定尺为11.9 m时,4流生产只能满足Φ12 mm热轧带肋钢筋的轧制节奏,5流生产可以满足所有规格轧制节奏;拉速一定时,铸坯的最大等待时间随定尺的增大而增大,但生产中一般采用调整拉速来改变连铸坯平均等待时间,而非通过调整连铸坯定尺来实现;连铸坯输送过程,空冷到最低开轧温度所经历的时间应小于连铸坯的最大等待时间,此时直轧产线铸坯的直轧率最高;根据铸-轧通钢量相等的原则计算,方坯直轧应该采用少流数、高拉速,短定尺来组织生产,使铸-轧产能匹配同时减少直轧铸坯的头尾温差,降低生产事故风险;方坯直轧系统的主要问题是连铸坯剪切顺序、钢-轧节奏匹配问题、连铸坯的最大等待时间等3项核心问题。

高速线材Φ20.0 mm规格盘条开发

随着国家钢铁行业的发展,市场对于冷墩钢、硬线等深加工产品的需求越来越大,特别是大规格盘条的需求。为满足客户的个性化要求,广西钢铁集团有限公司热轧总厂在高速线材生产线上对Φ20 mm规格线材盘条进行开发。结合热轧总厂高速线材模块轧机的特点,通过优化轧制通道、孔型设计、导卫设计及轧制工艺,解决了生产过程中轧件难咬入K2孔型、吐丝及成品质量不稳定等问题,实现了Φ20 mm规格线材盘条的成功开发和批量轧制。成品尺寸、产品性能能够满足客户的需求,为后续不断拓展产品规格提供了参考。

The Numerical Simulation on Hollow Part's Precise Sizing Process With Cross-wedge Rolling

The hollow parts formed with cross-wedge rolling (CWR) have a wide application in many fields, such as architecture and automobile, etc. But the finished configuration of part’s cross section was always ellipse and it was hard to make it satisfied with traditional forming process. This paper proposed a FEM model of hollow workpiece of CWR in the sizing process, and simulated the deformation condition using the ANSYS program. Three kinds of parts with different wall thickness were calculated. Some stress and strain fields of the deformed hollow parts at various conditions are gained. The influence of wall thickness on the distribution of stress and strain was analyzed. The paper also found two phenomena, which never have been seen at traditional experiment, and author tried to give some explanations. The ANSYS program provided the relationship between the tolerance of the deformed workpiece and the deforming parameter. It is helpful to design the sizing dies of a new precise forming process of hollow parts on the CWR. The new process that designed through the information of FEM improved the accuracy of hollow parts on CWR. It proved the validity and practicability of numerical simulation.

Influence of process parameters on the microstructural evolution of a rear axle tube during cross wedge rolling

In the shaping process of cross wedge rolling（CWR）, metal undergoes a complex microstructural evolution, which affects the quality and mechanical properties of the product. Through secondary development of the DEFORM-3D software, we developed a rigid plastic finite element model for a CWR-processed rear axle tube, coupled with thermomechanical and microstructural aspects of workpieces. Using the developed model, we investigated the microstructural evolution of the CWR process. Also, the influence of numerous parameters, including the initial temperature of workpieces, the roll speed, the forming angle, and the spreading angle, on the grain size and the grain-size uniformity of the rolled workpieces was analyzed. The numerical simulation was verified through rolling and metallographic experiments. Good agreement was obtained between the calculated and experimental results, which demonstrated the reliability of the model constructed in this work.

Effects of microrolling parameters on the microstructure and deformation behavior of pure copper

Microrolling experiments and uniaxial tensile tests of pure copper under different annealing conditions were carried out in this paper. The effects of grain size and reduction on non-uniform deformation, edge cracking, and microstructure were studied. The experimen- tal results showed that the side deformation became more non-uniform, resulting in substantial edge bulge, and the uneven spread increased with increasing grain size and reduction level. When the reduction level reached 80% and the grain size was 65 μm, slight edge cracks occurred. When the grain size was 200 μm, the edge cracks became wider and deeper. No edge cracks occurred when the grain size was 200 μm and the reduction level was less than 60%; edge cracks occurred when the reduction level was increased to 80%. As the reduction level increased, the grains were gradually elongated and appeared as a sheet-like structure along the rolling direction; a fine lamellar structure was obtained when the grain size was 20 lam and the reduction level was less than 60%.