Bearing ring is the crucial component of bearing. With regard to such problems as material waste, low efficiency and high energy consumption in current process of producing large bearing ring, a new process named ＂ca...Bearing ring is the crucial component of bearing. With regard to such problems as material waste, low efficiency and high energy consumption in current process of producing large bearing ring, a new process named ＂casting-rolling compound forming technology＂ is researched by taking the typical 42CrMo slew bearing as object. Through theoretical analysis, the design criteria of the main casting-rolling forming parameters are put forward at first. Then the constitutive relationship model of as-cast 42CrMo steel and its mathematical model of dynamic recrystallization are obtained according to the results of the hot compression experiment. By a coupled thermal-mechanical finite element model for radial-axial rolling of bearing ring, the fraction of dynamic recrystallization is calculated and recrystallized grains size are predicated. Meanwhile, the effects of the initial rolling temperature and feed rate of idle roll on material microstructure evolution are analyzed. Finally, the industrial rolling experiment is designed and performed, based on the simulation results. In addition, mechanical and metallographic tests are conducted on rolled bearing ring to get the mechanical parameters and metallographic structure. The experimental data and results show that the mechanical properties of bearing ring produced by casting-rolling compound forming technology are up to industrial standard, and a qualified bearing ring can be successfully formed by employing this new technology. Through the study, a process of forming large bearing ring directly by using casting ring blank is obtained, which could provide an effective theoretical guidance for manufacturing large ring parts. It also has an edge in saving material, lowering energy and improving efficiency.展开更多
Based on turbulent theory, a 3D coupled model of fluid flow and solidification was built using finite difference method and used to study the influence of superheating degree and casting speed on fluid flow and solidi...Based on turbulent theory, a 3D coupled model of fluid flow and solidification was built using finite difference method and used to study the influence of superheating degree and casting speed on fluid flow and solidification, analyze the interaction between shell and molten steel, and compare the temperature distribution under different technological conditions. The results indicate that high superheating degree can lengthen the liquid-core depth and make the crack and breakout possible, so suitable superheating should be controlled within 35℃ according to the simulation results. Casting speed which is one of the most important technological parameters of improving production rate, should be controlled between 0. 85 m/min and 1.05 m/min and the caster has great potential in the improvement of blank quality.展开更多
The effect of commercial frequency electromagnetic field on the solidification structure and mechanical propertiesof copper hollow blanks prepared by horizontal continuous casting method was investigated. The results ...The effect of commercial frequency electromagnetic field on the solidification structure and mechanical propertiesof copper hollow blanks prepared by horizontal continuous casting method was investigated. The results show thatwhen the electromagnetic field is imposed, columnar grains are evidently refined and fine equiaxed grains areobtained in the inner side of the cross-section. Moreover, with the increase of input current, the equiaxed grain regionwidens and the grains distribute more uniformly in the circumferential direction. Meanwhile, the mechanical properties areremarkably improved by the application of electromagnetic field. When the input current is 140 A, the tensile strengthincreases 15% and the elongation increases 10%. However, the electromagnetic field has no effect on the distribution ofmicroelements.展开更多
According to turbulent theory and characteristics of beam blank continuous casting, 3-D model to represent the flow of beam blank mould is established. The predicted results indicate that the exit obliquity of up 15&#...According to turbulent theory and characteristics of beam blank continuous casting, 3-D model to represent the flow of beam blank mould is established. The predicted results indicate that the exit obliquity of up 15°(+15°) should be adopted, which will benefit the floatation of non-metallic inclusion and purification of the molten steel. When the nozzle angle is 120°, the flow pattern is reasonable. Proper nozzle depth can be 200mm. Turbulent kinetic of meniscus can be reduced by adopting the square nozzle and suitable area of side outlet when casting speed increases. The results are consistent with those of water model experiment, so the model is exact and reasonable. The model can provide important information for design of SEN and defining of immersion depth.展开更多
Finite element models of steady heat conduction for cross section of beam blank mold were developed by using ABAQUS software. The effect of mold grinding thickness, cooling water velocity, diameter of restrietor rods ...Finite element models of steady heat conduction for cross section of beam blank mold were developed by using ABAQUS software. The effect of mold grinding thickness, cooling water velocity, diameter of restrietor rods and water channel design on hot face temperature was analyzed in detail. Attention was focused on the peak temperature and temperature uniformity along hot face. The results showed that the peak temperature of existing mold, about 337.2 ℃, is located in the fillet, and two valleys of hot face temperature are found in flange corner and junction of wide face and narrow face, respectively. Decreasing mold thickness, increasing cooling water velocity and increasing diameter of restrictor rods can all reduce peak temperature and improve temperature uniformity along hot race at the expense of lower overall temperature. Redesigning the water channel can decrease peak temperature and thermal gradient of mold without lowering overall temperature of hot face. In particular, the small hole design can improve temperature uniformity across hot face and obtain the best advantage.展开更多
基金supported by Key Program of National Natural Science Foundation of China(Grant No.51135007)National Natural Science Foundation of China(Grant No.51075290)
文摘Bearing ring is the crucial component of bearing. With regard to such problems as material waste, low efficiency and high energy consumption in current process of producing large bearing ring, a new process named ＂casting-rolling compound forming technology＂ is researched by taking the typical 42CrMo slew bearing as object. Through theoretical analysis, the design criteria of the main casting-rolling forming parameters are put forward at first. Then the constitutive relationship model of as-cast 42CrMo steel and its mathematical model of dynamic recrystallization are obtained according to the results of the hot compression experiment. By a coupled thermal-mechanical finite element model for radial-axial rolling of bearing ring, the fraction of dynamic recrystallization is calculated and recrystallized grains size are predicated. Meanwhile, the effects of the initial rolling temperature and feed rate of idle roll on material microstructure evolution are analyzed. Finally, the industrial rolling experiment is designed and performed, based on the simulation results. In addition, mechanical and metallographic tests are conducted on rolled bearing ring to get the mechanical parameters and metallographic structure. The experimental data and results show that the mechanical properties of bearing ring produced by casting-rolling compound forming technology are up to industrial standard, and a qualified bearing ring can be successfully formed by employing this new technology. Through the study, a process of forming large bearing ring directly by using casting ring blank is obtained, which could provide an effective theoretical guidance for manufacturing large ring parts. It also has an edge in saving material, lowering energy and improving efficiency.
文摘Based on turbulent theory, a 3D coupled model of fluid flow and solidification was built using finite difference method and used to study the influence of superheating degree and casting speed on fluid flow and solidification, analyze the interaction between shell and molten steel, and compare the temperature distribution under different technological conditions. The results indicate that high superheating degree can lengthen the liquid-core depth and make the crack and breakout possible, so suitable superheating should be controlled within 35℃ according to the simulation results. Casting speed which is one of the most important technological parameters of improving production rate, should be controlled between 0. 85 m/min and 1.05 m/min and the caster has great potential in the improvement of blank quality.
文摘The effect of commercial frequency electromagnetic field on the solidification structure and mechanical propertiesof copper hollow blanks prepared by horizontal continuous casting method was investigated. The results show thatwhen the electromagnetic field is imposed, columnar grains are evidently refined and fine equiaxed grains areobtained in the inner side of the cross-section. Moreover, with the increase of input current, the equiaxed grain regionwidens and the grains distribute more uniformly in the circumferential direction. Meanwhile, the mechanical properties areremarkably improved by the application of electromagnetic field. When the input current is 140 A, the tensile strengthincreases 15% and the elongation increases 10%. However, the electromagnetic field has no effect on the distribution ofmicroelements.
文摘According to turbulent theory and characteristics of beam blank continuous casting, 3-D model to represent the flow of beam blank mould is established. The predicted results indicate that the exit obliquity of up 15°(+15°) should be adopted, which will benefit the floatation of non-metallic inclusion and purification of the molten steel. When the nozzle angle is 120°, the flow pattern is reasonable. Proper nozzle depth can be 200mm. Turbulent kinetic of meniscus can be reduced by adopting the square nozzle and suitable area of side outlet when casting speed increases. The results are consistent with those of water model experiment, so the model is exact and reasonable. The model can provide important information for design of SEN and defining of immersion depth.
文摘Finite element models of steady heat conduction for cross section of beam blank mold were developed by using ABAQUS software. The effect of mold grinding thickness, cooling water velocity, diameter of restrietor rods and water channel design on hot face temperature was analyzed in detail. Attention was focused on the peak temperature and temperature uniformity along hot face. The results showed that the peak temperature of existing mold, about 337.2 ℃, is located in the fillet, and two valleys of hot face temperature are found in flange corner and junction of wide face and narrow face, respectively. Decreasing mold thickness, increasing cooling water velocity and increasing diameter of restrictor rods can all reduce peak temperature and improve temperature uniformity along hot race at the expense of lower overall temperature. Redesigning the water channel can decrease peak temperature and thermal gradient of mold without lowering overall temperature of hot face. In particular, the small hole design can improve temperature uniformity across hot face and obtain the best advantage.
