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2013年 20卷 10期
刊出日期：2013-10-15
材料
工艺
工艺
1
SUN Liang-liang,WANG Xiu-ying
Application of Mix Optimization Scheduling Approach for Steelmaking Continuous Casting Process Based on Actual Steelmaking Industry
The models, algorithms and implementation results of a computerized scheduling system were introduced for the steelmaking-continuous casting process (SCCP) of a steel plant in China. The scheduling of SCCP in this plant required that each cast plan should be processed on time, the charges in the same cast should be processed continuously on the same caster, and the waiting time of the charges which are in front of each caster cannot exceed the given threshold. At the same time, the processing time of charges cannot be conflicted mutually in the same converters or refining furnaces. Based on the research background, a hybrid optimal scheduling approach and its application were discussed. Aiming at the main equipment scheduling, an optimal scheduling method was proposed which consisted of equipment assignment algorithm based on dynamic program (DP) technique and conflict elimination algorithm based on linear program (LP) technique. The approach guarantees that the charges are continuously processed on the same caster. Meanwhile, the requirement for high temperature ladle can also be satisfied due to the ladle matching function. Numerical results demonstrate solution quality, computational efficiency, and values of the models and algorithm.
2013 Vol. 20 (10): 1-9 [
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10
ZHANG Guang-ji,LIU Xiang-hua,HU Xian-lei,ZHI Ying
Horizontal Velocity of Variable Gauge Rolling: Theory and Finite Elements Simulation
Within the production chain of longitudinal profiled (LP) plates and tailor rolled blanks (TRB), variable gauge rolling (VGR) represents the vital important forming stage, in which shape and properties are tailored to satisfy customers′ requirements. It is of vital importance to reveal the relationship between work-piece horizontal velocity and roll vertical velocity during VGR, which is not only a key point to understand the deformation law, but also an important content for setting VGR process parameters. It is proved that the simplified assumption of equal discharge per second condition (EDSC) breaks down during VGR. Due to this reason the differential equation of the work-piece horizontal velocity (VGR-V) is performed by keeping the material volume constant. To attain a comprehensive understanding of this underlying process in detail, numerical approaches based on finite elements method have been performed by utilizing the Abaqus Explicit. Rolling experiment is carried out which indicates that the numerical result coincides with the experimental result well. A fine spatial discretization of work-piece is essential for special emphasis has to be put on detecting different horizontal velocity of work-piece cross section, often leading to a hundred thousand degrees of freedom even for plane strain calculations. The data obtained by using Abaqus Explicit coincide with the results determined by theory. A theoretical basis on deformation parameters and mechanical parameters during VGR process is provided.
2013 Vol. 20 (10): 10-16 [
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17
JIA Chun-yu,SHAN Xiu-ying,CUI Yan-cao,BAI Tao,CUI Fa-jun
Modeling and Simulation of Hydraulic Roll Bending System Based on CMAC Neural Network and PID Coupling Control Strategy
The hydraulic roll bending control system usually has the dynamic characteristics of nonlinearity, slow time-variance and strong outside interference in the rolling process, so it is difficult to establish a precise mathematical model for control. So, a new method for establishing a hydraulic roll bending control system is put forward by cerebellar model articulation controller (CMAC) neural network and proportional-integral-derivative (PID) coupling control strategy. The non-linear relationship between input and output can be achieved by the concept mapping and the actual mapping of CMAC. The simulation results show that, compared with the conventional PID control algorithm, the parallel control algorithm can overcome the influence of parameter change of roll bending system on the control performance, thus improve the anti-jamming capability of the system greatly, reduce the dependence of control performance on the accuracy of the analytical model, enhance the tracking performance of hydraulic roll bending loop for the hydraulic and roll bending force and increase system response speed. The results indicate that the CMAC-PID coupling control strategy for hydraulic roll bending system is effective.
2013 Vol. 20 (10): 17-22 [
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23
CUI Li,SHI Quan-qiang,LIU Xiang-hua,HU Xian-lei
Residual Curvature of Longitudinal Profile Plate Roller in Leveling Process
Roller leveling process of longitudinal profile (LP) plate is hardly studied because plate thickness changes. Deformation characteristics and residual curvature during LP plate leveling process were investigated based on curvature integral by elastic-plastic differences. It was found that entry intermesh section is reduced with increasing thickness and entry intermesh should be from 07 to 11 mm for LP plate with 42/54 mm in thickness. In order to get satisfactory flatness along longitudinal direction, small entry intermesh should be selected and exit intermesh should be 0 mm. In addition, thickness section for LP plate which can be leveled by 11 roller leveler is from 24 to 60 mm. Finally, there is an intermesh schedule that could level LP plate with initial curvature less than elastic limit curvature.
2013 Vol. 20 (10): 23-27 [
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28
CHEN Jin-xiang,YANG Wei-dong,SUN Yan-guang
H∞ Control of Looper-Tension Control Systems Based on a Discrete-Time Model
High control performances cannot be obtained by most of the existing looper-tension control approaches through only considering controller designs based on continuous-time models, which cannot meet the requirements of modern computer control systems with high control accuracy. In order to solve the above problems, a state feedback H∞ control method based on a discrete-time model for looper-tension control systems in hot rolling mills is presented. The considered system is approximated by a discrete-time looper-tension control system model. Based on a Lyapunov functional method, a state feedback H∞ control law is developed which makes the closed-loop system asymptotically stable with guaranteed H∞ performance. The controller gains are obtained by solving a set of linear matrix inequalities (LMIs). In contrast to the existing results, the proposed approach can obtain good H∞ performance and effectively reduce external disturbances. The strip tension is also less affected by the change of looper angel, so good control performances can be obtained. Moreover, this control scheme is easy to implement, and can be applied to other linear systems. A simulation example with practical parameters is provided to illustrate the effectiveness of the developed method.
2013 Vol. 20 (10): 28-31 [
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32
ZHU De-qing,RUAN Zhi-yong,,CHUN Tie-jun,PAN Jian
Utilization of High Sulfur Raw Materials in Iron Ore Pellets
Pyrite cinder and high sulfur magnetite were used as raw materials to produce iron ore pellets. Good qualities of green balls and fired pellets were obtained from the feed comprising 50% pyrite cinder and 50% high sulfur magnetite concentrate at a small scale. Small-scale tests were proven by pilot-scale tests. The high grade fired pellets, assaying 6322% Fe, were analyzed, and the compressive strength of fired pellets was over 2500 N/pellet. The fired pellets possessed excellent metallurgical performances, such as reducibility index higher than 67%, reduction swelling index lower than 15% and low temperature reduction degradation index (+315 mm) higher than 1%, which can be used as the burden for blast furnace.
2013 Vol. 20 (10): 32-38 [
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39
XIAO Hong,,YUAN Zheng-wen,,WANG Tao,
Roll Flattening Analytical Model in Flat Rolling by Boundary Integral Equation Method
In order to improve rolled strip quality, precise plate shape control theory should be established. Roll flattening theory is an important part of the plate shape theory. To improve the accuracy of roll flattening calculation based on semi-infinite body model, especially near the two roll barrel edges, a new and more accurate roll flattening model is proposed. Based on boundary integral equation method, an analytical model for solving a finite length semi-infinite body is established. The lateral surface displacement field of the finite length semi-infinite body is simulated by finite element method (FEM) and lateral surface displacement decay functions are established. Based on the boundary integral equation method, the numerical solution of the finite length semi-infinite body under the distributed force is obtained and an accurate roll flattening model is established. Different from the traditional semi-infinite body model, the matrix form of the new roll flattening model is established through the mathematical derivation. The result from the new model is more consistent with that by FEM especially near the edges.
2013 Vol. 20 (10): 39-45 [
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46
Zbigniew Pater
Multi-Wedge Cross Rolling of Balls
The multi-wedge cross rolling process of forming balls is described. The process tool for rolling 8 balls with a diameter of 35 mm is presented. The course of the rolling process, distributions of forming forces as well as maps of effective strain and temperature in the obtained balls are presented by finite element modeling (FEM). Experimental tests of simultaneous forming of 4 balls with a diameter of 22 mm conducted in laboratory conditions at Lublin University of Technology have proved that the balls obtained in multi-wedge cross rolling are of good quality and can therefore be used in both ball mills and rolling bearings.
2013 Vol. 20 (10): 46-50 [
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51
ZHU Hang-yu,LI Zheng-bang,YANG Hai-sen,LUO Lin-gen
Carbothermic Reduction of MoO3 for Direct Alloying Process
The thermodynamics of Mo-O-C and Ca-Mo-O-C systems was studied in order to understand the carbothermic reduction of molybdenum trioxide, and kinetic studies were also carried out by means of thermogravimetric analysis under argon atmosphere with a heating rate of 10 ℃/min. Subsequently, reaction products at various temperatures were identified by X-ray diffraction (XRD) and the results confirmed the previous thermodynamics analysis. Meanwhile, it was found that intermediate products MoO2 and CaMoO4 appeared in the process of carbothermic reduction of MoO3 with or without CaO, which were subsequently reduced to Mo or molybdenum carbide. An experimentally determined reaction mechanism was proposed and discussed. The reduction reaction of MoO3 with carbon could be divided into two stages. The first stage includes the direct reaction between MoO3 and carbon and the carbon gasification reaction. The second stage is the gas-solid reaction between CO and MoO2, and the diffusion of gases through the surface of MoO2 determines the overall reaction rate. The activation energies of the mixtures with or without CaO were estimated to be 566 and 529 kJ/mol, respectively.
2013 Vol. 20 (10): 51-56 [
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57
Kowalik Marek,Trzepieciński Tomasz
Experimental and Numerical Study on Determination of Forces During Cold Rolling of Shafts
The influence of stress and friction conditions on material flow during longitudinal cold rolling of a shaft was investigated. The longitudinal cold rolling method makes it possible to form and finish-up machine parts in the rolling process, which is associated with strengthening of the material due to cold work. The experiments were carried out in order to determine the pressure force at the stage of squeezing on shafts formed by longitudinal cold rolling and made of constructional unalloyed steels S235JR and C45. The experimental results were compared with numerical simulation results obtained by using the MSCMarc 2010 based on finite element method (FEM). The influence of deformation degree on structural changes and the increase of material strength are shown.
2013 Vol. 20 (10): 57-63 [
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64
Dilipak Hakan,zdemir Mustafa,Sarikaya Murat
Effects of Material Properties and Punch Tip Radius on Spring-Forward in 90° V Bending Processes
Bending process is one of the most significant fields of application of sheet metal die. Sheet metals are exposed to some spring-back or spring-forward depending on elastic deformation following bending process. S235JR (10038) materials having a thickness of 4 mm were bent with 90° punches having 5 different tip radiuses. The bending process was carried out by making the punch waited on the material for 30 s (30 s wait bending) and by removing the punch without waiting (direct bending). Specimens were prepared in three forms as non-heat-treated, normalized and tempered. At the same time, all experiments were performed at a deformation speed of 25 mm/min. As a result, it was determined that as punch tip radius increased, the amount of spring-forward decreased. Although normalizing process applied to specimens increased the amount of spring-forward, tempering process decreased it. The amount of spring-forward was decreased in 30 s wait bending process.
2013 Vol. 20 (10): 64-69 [
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材料
70
WANG Hong-po,SUN Li-feng,PENG Bo,JIANG Mao-fa
Inclusions for Ultra-pure Ferritic Stainless Steels Containing 21% Chromium
As stabilizing elements added into ultra-pure ferritic stainless steels, niobium and titanium react with carbon and nitrogen to form carbonitrides and have great effects on the ratio of equiaxed zone and the grain size of solidification structure of ingots, which remarkably affect the quality of cold-rolled sheets. Combined with thermodynamic calculation, style and precipitation progress of inclusions in ultra-pure ferritic stainless steels were investigated by optical microscopy, scanning electron microscopy, transmission electron microscopy and energy dispersive spectroscopy. The results indicate that the inclusions are mainly Ti-Al-N-O system inclusions in ultra-pure ferritic stainless steels. Al2O3 starts to precipitate firstly and then TiOx and TiN precipitates sequently. The inclusions are mainly single TiN particles and complex inclusions with Al2O3-Ti2O3 as cores and covered with TiN under the condition of 031% titanium addition and mainly Al2O3 under the condition of 001% titanium addition. A few (Nb,Ti)N particles precipitate because of no enough titanium to react with nitrogen when titanium addition is 001%. In addition, fine Nb(C,N) particles with size of less than 500 nm precipitate at relatively low temperature.
2013 Vol. 20 (10): 70-74 [
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MI Zhen-li,JIANG Hai-tao,LI Zhi-chao,CHEN Mei-fang,WANG Zhi-gang
Effect of Finishing Rolling Temperature on Microstructure and Mechanical Properties of Microalloyed TRIP Steels
Different samples of TRIP (transformation induced plasticity) steel obtained by two different hot-rolling schedules are investigated by using a SEM (scanning electron microscope). The microstructure is characterized by using an OM (optical microscope) for phase distribution and by EBSD (electron backscatter diffraction) for texture and phase mapping. ODF (orientation distribution function) graphs are used to investigate the effect of recrystallization behavior of the hot-deformed austenite on phase transformation during the controlled cooling process. The mechanical behavior is interpreted in terms of the strength of both hard and soft phases, in combination with the quantity, location and transformation kinetics of the mechanically induced martensite (TRIP effect). The results show that more austenite grains exist in the steels obtained at finishing rolling temperature (FRT) of 750 ℃, which inherited the deformation structure after the hot-rolling process. The instantaneous n value (ni) of those steels is kept high during a large range of strain before failure, while the tensile strength and total elongation of the steels with respect to the different finishing rolling temperatures do not show any significant differences.
2013 Vol. 20 (10): 75-80 [
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81
YANG Zi-run,LI Dong-sheng,WANG Lan,WANG Shu-qi,WEI Min-xian
Wear Behavior and Mechanism of Spheroidal Graphite Cast Iron
Wear behavior and mechanism of spheroidal graphite cast iron were studied on a pin-on-disk elevated temperature wear tester. The phase and morphology of worn surfaces were examined by X-ray diffraction and scanning electron microscopy. Results show that with an increase of load, wear rate of spheroidal graphite cast iron gradually increases under low loads, rapidly increases or potentially increases under high loads; wear rate increases with increasing ambient temperature. At 25-200 ℃, adhesive wear prevails; oxidative wear and adhesive wear coexist at 400 ℃. As load surpasses 150 N at 400 ℃, extrusive wear appears. The elevated-temperature wear of spheroidal graphite cast iron is a physical and chemical process including the following reactions: xFe+y/2O2—FexOy, 2C+O2—2CO and FexOy+yCO—xFe+yCO2. Hence, at 400 ℃, the amount of graphite and tribo-oxides are substantially reduced because of reductive function of graphite. It can be suggested that wear-reduced effect of graphite and tribo-oxides is impaired.
2013 Vol. 20 (10): 81-86 [
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YUAN Lin-jiang,LUO fang,,YAO Jian-hua
Deposition Behavior at Different Substrate Temperatures by Using Supersonic Laser Deposition
The supersonic laser deposition (SLD) is a new fabrication process which combines the supersonic powder stream found in cold spray with laser heating of the deposition zone. Because of the instantaneity of particles impact, the deformation behaviors and the adhesion behaviors of particles impacted on the substrate by SLD cannot be well investigated through experiments. Therefore, a finite element model was developed to solve the problems above. Meanwhile, the heat effect of the substrate heated by laser was discussed. The effective plastic strain and the effective stress between the particle and substrate at different laser preheat temperatures were studied. The results show that laser depositing temperatures of 1000 and 1100 ℃ on substrate would be the optimized for the bonding of particles and substrate. In addition, the simulation results conformed to experimental results.
2013 Vol. 20 (10): 87-93 [
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94
JIN Guang-can,CHEN Shu-ying,LI Qing-chun,CHANG Guo-wei,YUE Xu-dong
In-Situ Observation of Proeutectoid Ferrite Growth Process in Carbon Steel Under Continuous Cooling Conditions
The growth of proeutectoid ferrite in Fe-015%C-08%Mn carbon steel during continuous cooling process was observed in-situ and tracked dynamically by using a high-temperature confocal scanning laser microscope (HTCSLM), and the growing process was also investigated. The growth regularity of proeutectoid ferrite plates within austenite was obtained by analyzing the growth fashions and directions and quantitatively studying the growth rates. The results show that the proeutectoid ferrite plates grow in the fashion of creeping, twisting, branching off and deflection within austenite grain. The proeutectoid ferrite plates can grow up along preferential orientation but not strictly. Its growth direction fluctuates and changes in a small range. The growth rate also changes with the change in growth fashion and direction. When the proeutectoid ferrite grows in the fashion of deflection, the average growth rate of proeutectoid ferrite before its deflection is about 619, and 462 μm/s after the 15° deflection. At the beginning of proeutectoid ferrite growing, there is a fast growing stage. As the tip of proeutectoid ferrite extends forward continuously, the growth rate will slow down. Therefore, it will induce the proeutectoid ferrite to deflect and grow along another favorable direction, then it will grow rapidly again.
2013 Vol. 20 (10): 94-98 [
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99
SHAO Yuan-yuan,YANG Ping,FU Yong-jun,,MAO Wei-min
Texture Evolution of Columnar Grains in Electrical Steel During Hot Rolling
Columnar grains in cast slabs of electrical steel show strong anisotropy in grain orientation and morphology and thus influence the subsequent microstructure and texture after hot rolling significantly. The texture evolution of hot rolled sheets containing initial columnar grains with their <100> directions approximately parallel to the rolling direction (RD), transverse direction (TD) and normal direction (ND) of the hot rolled sheets was investigated by using EBSD technique. The results indicated that, whatever the initial texture of the columnar grains was, typical Goss, brass-type and copper-type shear texture component could develop in shear-deformed surface region. The copper-type texture formed under the maximum shearing force with the fine, sheared or dynamically recrystallized grains, and Goss grains were mainly elongated and deformed grains, while brass grains behaved between them. Additionally, the rotating relationship of the three types of shear textures was different due to the restriction of grain boundaries. In homogenously deformed center region, the RD sample contained more {112}<110> grains, and TD sample was covered by {100} textures such as {100}<011> and {100}<021> with coarse grains, while the ND sample developed many {100}<001> grains which were attributed to more {100} grains in the initial sample. Remarkable texture transition occurred on both sides of grain boundaries when {110} grains were adjacent to α-fiber texture grains. It was found that significant texture gradient and preferred distribution of rotating axis existed in the soft orientation grains on the α-fiber when the grains neighbored hard grains on γ-fiber.
2013 Vol. 20 (10): 99-106 [
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107
WANG Chang-jun,FENG Han,ZHENG Wen-jie,SONG Zhi-gang,YONG Qi-long
Dynamic Recrystallization Behavior and Microstructure Evolution of AISI 304N Stainless Steel
Dynamic recrystallization of 304N stainless steel was investigated at deformation temperatures of 900-1300 ℃ and strain rates of 001-10 s-1 by a Gleeble-1500 thermo-mechanical simulator. And the microstructure evolutions of specimens with different deformation temperatures were observed by using a transmission electron microscope. Results indicated that compared with conventional AISI 304 austenitic stainless steel, 304N stainless steel has higher deformation resistance force and deformation activation energy under similar conditions. In addition, the flow stress constitutive equation of 304N stainless steel was obtained by regression analysis of experimental stress-strain data, and the calculated values proposed by the mathematical model agree well with the experimental results.
2013 Vol. 20 (10): 107-112 [
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113
WANG Jing-zhong,LIU Zheng-dong,BAO Han-sheng,CHENG Shi-chang
Evolution of Precipitates of S31042 Heat Resistant Steel During 700 ℃ Aging
The evolution of precipitates of S31042 steel during 700 ℃ aging was investigated by using a scanning electron microscope, a transmission electron microscope, and electron energy spectrum technology. The various combinations of M23C6, MX, NbCrN, and σ and G phases in the steel were found at different aging states. In the beginning of aging, M23C6 precipitates swiftly along the grain boundaries. When the aging time exceeds 6000 h, precipitated M23C6 carbides along the grain boundaries turn to be granular. It was found that Si element segregates to grain boundaries during above process, which may enhance the granular shape of M23C6 carbides and its transformation to σ and G phases. When the aging time exceeds 10000 h, various shaped σ phase and granular G phase appear along the grain boundaries and there are no continuous M23C6 carbides along the grain boundaries. Meanwhile, a large quantity of granular M23C6 carbides and a minor amount of G phase precipitate near the grain boundaries. Based on the segregation of silicon to the grain boundaries, a precipitation evolution model during aging was concluded.
2013 Vol. 20 (10): 113-121 [
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122
J H Ramírez-Ramírez,R Colás,N F Garza-Montes-de-Oca
High Temperature Oxidation of a Work Roll Grade High-Chromium White Cast Iron
High-chromium white cast iron is a common material for the manufacture of the work rolls used in the finishing stands in hot strip mills. The high temperature oxidation behaviour of as-cast and heat-treated high-chromium white cast iron was studied by gravimetric means at 650 ℃ in atmospheres that included dry air and a mixture of dry air and water vapour. For both environmental and material conditions, the oxidation rate of the alloys was represented by parabolic trends and the oxidation phenomenon was more obvious when the samples were oxidised in water vapour. Water vapour also influenced the chemical composition of the oxides formed in the alloy and under this condition, the oxide scale formed on the alloy contained the oxides FeCr2O4, (Fe,Cr)3O4 and (Fe,Cr)2O3. In contrast, the alloys exposed to dry air conditions only experienced the formation of FeCr2O4 and (Fe,Cr)2O3. It was found that the presence of water vapour and the chromium content of the alloys increased the oxidation rate by a mechanism that involved chromium depletion of the oxide as a result of hydroxide formation. The differences observed in the oxidation behaviour of the alloy are discussed in terms of the composition of the oxidant atmosphere and the metallurgical condition of the specimens.
2013 Vol. 20 (10): 122-129 [
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