Quantitative evaluation of multi-process collaborative operation in steelmaking–continuous casting sections

The quantitative evaluation of multi-process collaborative operation is of great significance for the improvement of production planning and scheduling in steelmaking–continuous casting sections(SCCSs). However, this evaluation is difficult since it relies on an in-depth understanding of the operating mechanism of SCCSs, and few existing methods can be used to conduct the evaluation, due to the lack of full-scale consideration of the multiple factors related to the production operation. In this study, three quantitative models were developed, and the multiprocess collaborative operation level was evaluated through the laminar-flow operation degree, the process matching degree, and the scheduling strategy availability degree. Based on the evaluation models for the laminar-flow operation and process matching levels, this study investigated the production status of two steelmaking plants, plants A and B, based on actual production data. The average laminar-flow operation(process matching) degrees of SCCSs were obtained as 0.638(0.610) and 1.000(0.759) for plants A and B, respectively, for the period of April to July 2019. Then, a scheduling strategy based on the optimization of the furnace-caster coordinating mode was suggested for plant A. Simulation experiments showed higher availability than the greedy-based and manual strategies. After the proposed scheduling strategy was applied,the average process matching degree of the SCCS of plant A increased by 4.6% for the period of September to November 2019. The multi-process collaborative operation level was improved with fewer adjustments and interruptions in casting.

Reversing design methodology of investment casting die profile based on ProCAST

Turbine blade is one of the critical components of aircraft engine.The performance of the engine depends on the shape and dimensions of components,but superalloy blade material cannot be easily machined.Although investment casting is an ideal process for such net-shape components,it requires an accurate determination of the casting-die profile.In this paper,a reversing design methodology for investment casting die using ProCAST is proposed.By combining the methods of simplifying grid files and quick sorting,the efficiency of sorting and matching can be largely improved.Further,the mould/die cavity anti-deformation system can be easily built.With ProCAST,the optimized die profile for investment casting can be established.

Tape casting of borosilicate glass/Al_2O_3 composites for LTCC substrate with various relative molecular masses of PVB

The dispersion, stabilization and rheological properties of the slurry with various relative molecular masses of PVB were studied. The sintering properties, microstructure and dielectric properties of borosilicate glass/Al2O3 composites were also investigated. The intensities of the typical vibrating bands decrease with the decrease of the relative molecular mass of PVB, which demonstrates that the content of butyral groups in PVB binders decreases correspondingly, leading to a rapid decrease in the viscosity of the mixed slurry. The solid content of samples increases with the decrease of the relative molecular mass of PVB, and this further leads to the increase of tape thickness, bulk density and dried-shrinkage coefficient of tapes. The bulk density, relative density, three-point strength and dielectric constant of sintered samples increase with the increase of the solid content, and the shrinkage and dielectric loss decrease. By contrast, samples for PVB-5s exhibit better properties of a bulk density of 3.10g/cm3 , a relative density of 98.1%, a three-point strength of 208 MPa, a ε r value of 8.01, a tanδ value of 7.6×10-4 at 10 MHz and a well matching with Ag electrodes.

合金灰口铸铁气缸套组织形貌与耐磨性研究

针对5种成分和组织的灰口铸铁气缸套,包括2种贝氏体铸铁气缸套和3种珠光体铸铁气缸套,全面分析了其成分、相组成及硬度等材料特性,将喷钼活塞环与5种合金灰口铸铁气缸套对磨,通过比较各配对副的摩擦磨损性能,获得了喷钼活塞环与5种合金灰口铸铁气缸套的匹配规律。研究结果表明:5种气缸套材料均为由硬质相、基体和石墨构成的复合耐磨结构,各组分的性能、分布及其配比,是决定耐磨性的关键因素。珠光体基体气缸套的磨损量相对稳定,气缸套与活塞环的相对磨损量正常;铸态贝氏体气缸套磨损较轻,配对活塞环的磨损量比珠光体气缸套大;贝氏体气缸套和活塞环的磨损均量很小。

基于ProCAST仿真文件的精铸模具反变形方法

基于ProCAST数值模拟网格文件,提出了一种精铸模具反变形方法。首先提取所需网格文件中节点信息,将无序节点进行匹配变为有序节点。网格文件简化法与快速排序法的结合提高了排序匹配的效率。建立了模具反变形系统,经验证,所采用的方法取得了良好的效果。

High-Speed Machining of Malleable Cast Iron by Various Cutting Tools Coated by Physical Vapor Deposition

The coating material of a tool directly affects the efficiency and cost of machining malleable cast iron.However,the machining adaptability of various coating materials to malleable cast iron has been insufficiently researched.In this paper,turning tests were conducted on cemented carbide tools with different coatings(a thick TiN/TiAlN coating,a thin TiN/TiAlN coating,and a nanocomposite(nc)TiAlSiN coating).All coatings were applied by physical vapor deposition.In a comparative study of chip morphology,cutting force,cutting temperature,specific cutting energy,tool wear,and surface roughness,this study analyzed the cutting characteristics of the tools coated with various materials,and established the relationship between the cutting parameters and machining objectives.The results showed that in malleable cast iron machining,the coating material significantly affects the cutting performance of the tool.Among the three tools,the nc-TiAlSiN-coated carbide tool achieved the minimum cutting force,the lowest cutting temperature,least tool wear,longest tool life,and best surface quality.Moreover,in comparisons between cemented-carbide and compacted-graphite cast iron machined under the same conditions,the wear mechanism of the coated tools was found to depend on the cast iron being machined.Therefore,the performance requirements of a tool depend on multiple factors,and selecting an appropriately coated tool for a particular cast iron material is essential.

基于测量点云的涡轮叶片配准定位算法应用研究

涡轮叶片是航空发动机的核心零件,其精铸后进行数控机加需要先实现叶片测量点云与CAD模型的快速、准确配准定位。为此,针对测量点云初始位姿不佳的问题,实现了基于主成分分析的预对齐和手工关联预对齐两种预对齐算法;针对匹配点计算效率较低的问题,实现了网格法、赋范空间投影法和基于kd–tree快速搜索法3种搜索算法,通过对比分析发现,基于kd–tree搜索算法计算效率较好。在此基础上,确定了手工关联预对齐、基于kd–tree快速搜索匹配点集和ICP方法的配准方案,示例测量点云配准定位后与CAD模型差异区间为[–0.06 mm,+0.1 mm],符合涡轮叶片铸造精度情况。

PC板式加劲梁悬索桥上部结构施工控制研究

针对预应力混凝土(PC)板式加劲梁悬索桥施工过程中加劲梁出现的线形不平顺和湿接缝易开裂问题,以某大跨径PC板式加劲梁悬索桥为背景,采用MIDAS软件建立主桥空间杆系有限元模型,分析加劲梁临时连接匹配精度、梁段间临时铰转动模式、湿接缝浇筑对加劲梁成桥线形及湿接缝应力的影响,并提出相应的施工控制措施。结果表明:加劲梁采用场内预拼,并以预制精度较高的加劲梁底板作为高程控制点,以及提高临时连接锚固件的制造和安装精度,可确保梁段间临时连接匹配精度;在加劲梁底部设置挡块,将临时铰转动模式固化为单向铰,保证了加劲梁吊装过程中线形平顺;湿接缝浇筑采用全跨水袋等代配重控制措施,加劲梁线形良好,湿接缝无开裂现象。

钛合金精密铸造用陶瓷模壳研究

对适用于钛合金精密铸造用陶瓷模壳的制备工艺进行了系统的实验分析,表征了以过渡金属氧化物溶胶为粘结剂、稳定氧化锆为耐火材料的料浆的性能并讨论了相关参数的影响,对比研究了级配粉与均匀细粉制作的模壳的表面质量.结果表明,粗/细粉含量等级配参量和粉液比通过影响密度、粘度、滞流率以及涂层厚度等工艺参数而影响模壳的表面质量.在上述分析基础上确定了适用于本实验条件下钛合金精密铸造用陶瓷模壳的制备工艺参数.

Bi_2O_3掺杂堇青石陶瓷坯片与导电银浆共烧行为的研究

采用Bi2O3进行掺杂,成功地将堇青石陶瓷坯片的烧结温度降低到900℃。利用水基流延法制备堇青石坯片,研究了堇青石流延坯片的性能及其与导电银浆的共烧行为。结果表明,在900℃烧结的堇青石陶瓷坯片主晶相为α相,烧结试样具有良好的致密性和介电性能,且与导电银浆具有较好的共烧匹配性。

超声铸造工具杆端面优化设计及模态分析

基于原工具杆,根据Snell定律,综合考虑半连铸时的金属液穴形状、声强度分布及声能利用率,对其端面进行优化,研究并设计了一种新的适合铝合金超声铸造的工具杆,利用有限元方法,采用MSC.Marc软件分析工具杆的共振模态。对比优化前后工具杆的纵向振动频率,发现两者几乎相等,从而验证了设计的准确性,满足匹配要求。优化后的工具杆可以和原振动系统匹配使用,且符合半连铸工况,工作性能良好。

电感耦合等离子体原子发射光谱法测定稀土镁铸铁中常量及痕量元素

建立了利用电感耦合等离子体原子发射光谱法(ICP-AES法)同时测定稀土镁铸铁中常量及痕量共12种元素(Si,Mn,P,Cu,Mo,V,Ti,Sn,Sb,Mg,La,Ce)的分析方法。研究了稀土镁铸铁试样的前处理方法、优选了适宜的仪器测定参数和分析谱线,采用基体匹配法进行基体效应的校正。实验结果表明,各元素分析谱线线性相关系数大于0.999 0,方法检出限在0.000 12%～0.001 4%之间。方法用于稀土镁铸铁标准物质分析,测定值与认定值相符,测定结果的相对标准偏差在0.59%(Si)～6.9%(La)范围。

水钢转炉到连铸工序的物流衔接匹配

在水城钢铁公司炼钢厂现场实测数据的基础上,结合该厂的生产设备、环境对转炉-精炼-连铸的工序时间、物流量、生产容量进行了解析,并对各生产流程的物流调控进行了分析,找出了影响其物流绩效的因素,提出了各工序生产参数的优化值和合理的生产模式.

基于全连铸生产模式工序节奏优化的研究

对全连铸生产模式下各炉次在各机器加工过程中的路由路径和路由时间进行了解析。对炉次在处理过程中的路由选择、机器加工开始时间等目标变量进行了研究,以前后工序机器之间因等待引起的温降最小、准时交货和连浇连铸为约束条件,建立非线性规划模型,求解各炉次在不同机器上的开始处理时间,实现炼钢-连铸生产优化调度。生产实践表明,该方法正确、有效,可用于全连铸生产模式下的炉机生产计划的优化调度。

大型铝青铜衬套的离心铸造工艺研究

通过对大型铝青铜衬套的离心铸造,介绍了在我公司离心机设备的极限状态下,设备参数与铸型参数的匹配、铸型参数与铸件参数的匹配以及离心铸造工艺参数之间的匹配关系,讨论了铸型在加工过程中产生偏心时能否继续用于离心铸造,还对预防大型铝青铜衬套离心铸造生产中易产生的缺陷进行了探讨。

节段预制拼装波形钢腹板组合箱梁桥横向受力性能试验研究

为研究波形钢腹板组合箱梁桥横向受力特性及其对节段预制拼装工艺的影响,设计并匹配制造了2榀足尺模型节段梁,对试验梁施工全过程桥面板变形进行了测试,并进行了静力加载试验,研究了桥面板合理的数值分析方法.结果表明：波形钢腹板组合箱梁能满足节段双层存放、吊装运输等工序的横向受力要求,但在短线匹配预制过程中需采取措施控制桥面板变形;运营期组合箱梁横向受力足够安全,当加载至1.3~2.5倍车辆荷载设计值时,桥面板出现初始弯曲裂缝;由考虑钢混连接件的实体元模型计算所得的桥面板变形值与实测值吻合较好;简化平面框架模型则在横向内力计算方面具有足够精度,可用以指导桥面板设计.

炉条双面模板塑料模的设计与制造工艺

根据炉条铸件的结构特点及生产批量,设计脱箱造型用的双面模板塑料模,改进炉条的制模工艺,提高其铸件的产品质量与生产效率。经生产验证,用环氧树脂塑料制作的炉条双面模板塑料模完全满足其铸件零件的设计、工艺及生产要求。

硼硅酸盐复相材料与金属浆料共烧匹配性研究

采用流延法,制备了硼硅酸铅微晶玻璃/Al2O3复相玻璃陶瓷基片。考察了复相陶瓷与金属浆料在烧成过程中,由于异种材料收缩特性差异对CBS系LTCC材料与金属浆料共烧匹配性的影响。结果表明:850°C烧结试样,体积密度3.14g.cm-3,X、Y轴收缩率13%,Z轴收缩率17%,热膨胀系数6×10-6.K-1,热导系数为2.4W.(mK)-1,10MHz下介电常数和介电损耗分别为7.95和1.1×10-3,能够与金属电极浆料实现850°C共烧,匹配性良好,可满足LTCC基板材料的使用要求。

PC箱梁短线法节段预制施工技术

郑州桃花峪黄河大桥北引桥为3×(6×50)m+4×(50+4×51+50)m等高预应力混凝土连续梁桥,箱梁采用短线法节段预制、架桥机整孔拼装施工。箱梁节段自每跨中间向两端依次匹配预制,先浇筑完成节段作为相邻待浇节段的匹配段,匹配段采用底模台车多向精确定位。预制施工中,模板系统主要由固定端模及其钢支架、侧模及其钢支架、底模及底模台车、内模及滑车等组成;箱梁节段钢筋在钢筋绑扎台座成型,采用多点吊放入模并准确定位固定;箱梁C55混凝土集中拌制,用罐车运至制梁台座处,采用汽车泵浇筑;箱梁节段预制完成后存梁不少于3个月;箱梁横向预应力在预制场内张拉,纵向预应力在桥上施工;控制箱梁预制节段的中线、垂直度、水平度等线形满足规范要求。

大型厚壁螺母的离心铸造工艺研究

通过对冶金设备上大型高锰铝青铜厚壁螺母的离心铸造,介绍了如何在超出离心机设备能力的极限状态下,挖掘设备潜力进行铸型设计,优化参数匹配进行工艺设计,还介绍了合金液的炉前真空含气试验法及适用范围,并成功地浇注该铸件。提供了厚壁铸件发生淋落时临界状态下的内径尺寸,据此计算出三种转速公式的临界系数β、G、C,还对防止大型高锰铝青铜厚壁螺母在离心铸造生产中易产生的缺陷进行了探讨。