极薄箔带轧制的适轧厚度理论及数值模拟
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摘要
微制造、微电子行业的小型化、轻量化和移动化的发展方向需要厚度更薄、尺寸精度更高的极薄和超薄金属箔材,极薄和超薄金属箔材制造技术越来越重要。极薄带轧制试验及生产实际中,Stone最小可轧厚度公式有较多不合理之处。通过有限元模拟得到不同厚度极薄箔带在不同压下率时的接触轮廓与轧制压力变化规律,为Stone最小可轧厚度赋予新含义,即表示在极小压下变形量条件下是否存在中性区的临界厚度值;建立了极薄箔带适轧厚度解析计算模型,即根据轧制力条件和箔带厚度可计算出其单道次能够获得的最大压下量,为已有轧机确定产品规格范围并制定轧制规程及为设计轧机时确定轧辊直径和力学参数提供理论指导。
The miniaturization,lightweight and mobility of the micro-manufacturing and micro-electronics industries require the extreme-thin and the ultra-thin metal foil with a thinner thickness and a higher dimensional accuracy,thus the manufacturing technologies of the extreme-thin and the ultra-thin metal foil are becoming more and more significant.It is found that Stone's minimums rolling thickness is more unreasonable in the experiment and the production practice.The contact profile and the rolling pressure of the ultra-thin foil strip with different thicknesses at different reduction rates are obtained by means of the finite element simulation,which gives a new meaning to the Stone′s minimum rolling thickness formula,the critical thickness of whether there is a neutral zone under the condition of the minimum reduction deformation.An analytical calculation model for the gauge suitable to roll in the ultrathin strip rolling is established and the plastic deformation can be calculated according to the rolling force condition and the thickness of the foil strip,providing a theoretical guidance for the practical production by defining product specification ranges and rolling regulations for existing rolling mills and determining roller diameters or force and energy parameters when design rolling mills.
The miniaturization,lightweight and mobility of the micro-manufacturing and micro-electronics industries require the extreme-thin and the ultra-thin metal foil with a thinner thickness and a higher dimensional accuracy,thus the manufacturing technologies of the extreme-thin and the ultra-thin metal foil are becoming more and more significant.It is found that Stone's minimums rolling thickness is more unreasonable in the experiment and the production practice.The contact profile and the rolling pressure of the ultra-thin foil strip with different thicknesses at different reduction rates are obtained by means of the finite element simulation,which gives a new meaning to the Stone′s minimum rolling thickness formula,the critical thickness of whether there is a neutral zone under the condition of the minimum reduction deformation.An analytical calculation model for the gauge suitable to roll in the ultrathin strip rolling is established and the plastic deformation can be calculated according to the rolling force condition and the thickness of the foil strip,providing a theoretical guidance for the practical production by defining product specification ranges and rolling regulations for existing rolling mills and determining roller diameters or force and energy parameters when design rolling mills.
引文
[1]刘相华,宋孟,孙祥坤,等.极薄带轧制研究与应用进展[J].机械工程学报,2017,53(10):1.(LIU Xiang-hua,SONG Meng,SUN Xiang-kun,et al.Adcances in research and application of foil rolling[J].Journal of Mechanical Engineering,2017,53(10):1.)
[2]梁治国.高精压延电子铜箔产业现状与国产化对策浅析[J].新材料产业,2011(7):22.(LIANG Zhi-guo.Present situation of high precision calendering electronic copper foil industry and countermeasures for localization[J].Advanced Materials Inductry,2011(7):22.)
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[4]崔瑞强,吴伏家,李震,等.微型飞行器结构的发展及关键技术[J].机械工程与自动化,2012(1):197.(CUI Rui-qiang,WU Fu-jia,LI Zhen,et al.Development of MAV configurations and key techniques[J].Mechanical Engineering and Automation,2012(1):197.)
[5]白振华,蒋岳峰,李兴东,等.极薄带钢平整轧制过程辊端压靠问题[J].机械工程学报,2006,42(8):224.(BAI Zhenhua,JIANG Yue-feng,LI Xing-dong,et al.Kiss between roller ends in skin rolling process of super thin strip[J].Journal of Mechanical Engineering,2006,42(8):224.)
[6]员征文,肖宏,谢红飙.基于边界积分方程法的六辊轧机辊系变形分析[J].机械工程学报,2013,49(18):125.(YUAN Zheng-wen,XIAO Hong,XIE Hong-biao.6-HI mill deformation analysis based on boundary integral equation method[J].Journal of Mechanical Engineering,2013,49(18):125.)
[7]张勃洋,卢兴福,张立元,等.冷轧极薄带钢复杂板形翘曲变形行为研究[J].机械工程学报,2018,54(12):184.(ZHANG Bo-yang,LU Xing-fu,ZHANG Li-yuan,el al.Analysis of complex warping deformation for cold-rolled strip[J].Journal of Mechanical Engineering,2018,54(12):184.)
[8] Stone M D.Rolling of thin strip[J].Iron and Steel Engineer,1953,2:61.
[9] Stone M D.Rolling of thin strip partⅡ[J].Iron and Steel Engineer,1956,12:55.
[10] Pawelski O,Kading G.Causes of the limiting degree of deformations in the cold rolling of thin strip[J].Arch Eisenhuttenwesen,1970,41(3):249.
[11]吴首民.极薄带钢轧制过程中最小可轧厚度的研究[J].中国冶金,2007,17(3):10.(WU Shou-min.Research of smallest permissive rolling thickness during strip rolling[J].China Metallurgy,2007,17(3):10.)
[12] Ford H,Alexander J M.Rolling hard materials in thin gauges basic consideration[J].Journal of the Institute of Metals,1960,88(5):193.
[13] Fleck N A,Johnson K L.Towards a new theory of cold rolling thin foil[J].International Journal of Mechanical Sciences,1987,29(7):507.
[14] Fleck N A,Johnson K L,Mear M E,et al.Cold rolling of foil[J].Proceedings of the Institution of Mechanical Engineers,Part B:Journal of Engineering Manufacture,1992,206(2):119.
[15]肖宏,任忠凯,刘晓,等.极薄带轧制变形区轧辊压扁试验与有限元模拟[J].钢铁,2017,52(1):38.(XIAO Hong,REN Zhong-kai,LIU Xiao,et al.Experiment and finite element simulation of roll flattening in deformation zone for ultra-thin strip rolling[J].Iron and Steel,2017,52(1):38.)
[16] XIAO Hong,REN Zhong-kai,LIU Xiao.New mechanism describing the limiting producible thickness in ultra-thin strip rolling[J].International Journal of Mechanical Sciences,2017,133(11):788.
[17]任忠凯,肖宏,刘晓.极薄带最小可轧厚度理论及试验分析[J].钢铁,2017,52(8):60.(REN Zhong-kai,XIAO Hong,LIU Xiao.Theoretical and experimental analysis of minimum thickness in ultra-thin strip rolling[J].Iron and Steel,2017,52(8):60.)
[18]朱泉,于九明,齐克敏.冷轧薄板时的延伸困难问题与适轧厚度[J].东北工学院学报,1988,57(4):420.(ZHU Quan,YU Jiu-ming,QI Ke-min.Problem of reducibility in sheet cold-rolling and gauge suitable to roll[J].Journal of Northeast University of Technology,1988,57(4):420.)
[2]梁治国.高精压延电子铜箔产业现状与国产化对策浅析[J].新材料产业,2011(7):22.(LIANG Zhi-guo.Present situation of high precision calendering electronic copper foil industry and countermeasures for localization[J].Advanced Materials Inductry,2011(7):22.)
[3]穆晓枫,顾大强,陈柏,等.血管微型机器人无损伤体内驱动方法[J].浙江大学学报:工学版,2005,39(5):618.(MU Xiao-feng,GU Da-qiang,CHEN Bai,et al.New minimal invasive drive method of vascular micro-robot[J].Journal of Zhejiang University:Engineering Science,2005,39(5):618.)
[4]崔瑞强,吴伏家,李震,等.微型飞行器结构的发展及关键技术[J].机械工程与自动化,2012(1):197.(CUI Rui-qiang,WU Fu-jia,LI Zhen,et al.Development of MAV configurations and key techniques[J].Mechanical Engineering and Automation,2012(1):197.)
[5]白振华,蒋岳峰,李兴东,等.极薄带钢平整轧制过程辊端压靠问题[J].机械工程学报,2006,42(8):224.(BAI Zhenhua,JIANG Yue-feng,LI Xing-dong,et al.Kiss between roller ends in skin rolling process of super thin strip[J].Journal of Mechanical Engineering,2006,42(8):224.)
[6]员征文,肖宏,谢红飙.基于边界积分方程法的六辊轧机辊系变形分析[J].机械工程学报,2013,49(18):125.(YUAN Zheng-wen,XIAO Hong,XIE Hong-biao.6-HI mill deformation analysis based on boundary integral equation method[J].Journal of Mechanical Engineering,2013,49(18):125.)
[7]张勃洋,卢兴福,张立元,等.冷轧极薄带钢复杂板形翘曲变形行为研究[J].机械工程学报,2018,54(12):184.(ZHANG Bo-yang,LU Xing-fu,ZHANG Li-yuan,el al.Analysis of complex warping deformation for cold-rolled strip[J].Journal of Mechanical Engineering,2018,54(12):184.)
[8] Stone M D.Rolling of thin strip[J].Iron and Steel Engineer,1953,2:61.
[9] Stone M D.Rolling of thin strip partⅡ[J].Iron and Steel Engineer,1956,12:55.
[10] Pawelski O,Kading G.Causes of the limiting degree of deformations in the cold rolling of thin strip[J].Arch Eisenhuttenwesen,1970,41(3):249.
[11]吴首民.极薄带钢轧制过程中最小可轧厚度的研究[J].中国冶金,2007,17(3):10.(WU Shou-min.Research of smallest permissive rolling thickness during strip rolling[J].China Metallurgy,2007,17(3):10.)
[12] Ford H,Alexander J M.Rolling hard materials in thin gauges basic consideration[J].Journal of the Institute of Metals,1960,88(5):193.
[13] Fleck N A,Johnson K L.Towards a new theory of cold rolling thin foil[J].International Journal of Mechanical Sciences,1987,29(7):507.
[14] Fleck N A,Johnson K L,Mear M E,et al.Cold rolling of foil[J].Proceedings of the Institution of Mechanical Engineers,Part B:Journal of Engineering Manufacture,1992,206(2):119.
[15]肖宏,任忠凯,刘晓,等.极薄带轧制变形区轧辊压扁试验与有限元模拟[J].钢铁,2017,52(1):38.(XIAO Hong,REN Zhong-kai,LIU Xiao,et al.Experiment and finite element simulation of roll flattening in deformation zone for ultra-thin strip rolling[J].Iron and Steel,2017,52(1):38.)
[16] XIAO Hong,REN Zhong-kai,LIU Xiao.New mechanism describing the limiting producible thickness in ultra-thin strip rolling[J].International Journal of Mechanical Sciences,2017,133(11):788.
[17]任忠凯,肖宏,刘晓.极薄带最小可轧厚度理论及试验分析[J].钢铁,2017,52(8):60.(REN Zhong-kai,XIAO Hong,LIU Xiao.Theoretical and experimental analysis of minimum thickness in ultra-thin strip rolling[J].Iron and Steel,2017,52(8):60.)
[18]朱泉,于九明,齐克敏.冷轧薄板时的延伸困难问题与适轧厚度[J].东北工学院学报,1988,57(4):420.(ZHU Quan,YU Jiu-ming,QI Ke-min.Problem of reducibility in sheet cold-rolling and gauge suitable to roll[J].Journal of Northeast University of Technology,1988,57(4):420.)