热连轧带钢板形控制与辊型优化设计
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摘要
实现高精度的热轧带钢板形自动控制是热轧生产者孜孜不倦追求的目标。本文以东北大学轧制技术及连轧自动化国家重点实验室与韩国浦项(POSCO)的国际合作项目—‘'Development of CVC Roll Model and Thermal Crown Model for Hot Strip Mill"、与本钢热轧厂的合作项目—“提高1700mm热轧带钢板形控制精度的研究”以及与唐山港陆钢铁有限公司的合作项目—“港陆1250mm板形控制系统开发”为背景,系统地研究了热轧带钢板形控制基本理论与技术、辊型优化设计及热轧机组辊型优化配置。主要内容如下：
(1)建立了热连轧机板形控制设定系统。.详细地分析了热连轧带钢板形控制策略,以获得带钢出口目标凸度及板形良好为目标,考虑带钢在相邻机架间的协调关系,确定各机架带钢入口比例凸度。建立了负载条件下辊缝模型、轧辊横移位置及弯辊力计算模型。以某一换辊周期为例,计算了轧辊横移位置、弯辊力、并实测了带钢出口凸度及平直度偏差。
(2)采用影响函数法建立了辊系弹性变形数学模型,推导了CVC轧机工作辊弯辊力影响函数、轧辊弹性变形影响函数、工作辊压扁影响函数及辊间压扁影响函数,得出轧辊辊系弹性变形的力平衡方程、力—位移关系方程和变形协调方程。采用平滑指数和收敛指标取值的处理方法,有效地解决了辊系弹性变形计算精度及收敛问题。
(3)采用差分法建立了轴对称轧辊温度场模型。针对实际生产中某一换辊周期,用该模型求解的工作辊表面温度及热膨胀值与实测值吻合较好,验证了模型的实用性。
(4)采用“切片法”,同时考虑轧制过程中轧辊横移的影响,建立了轧辊磨损模型。计算了实际生产中某一换辊周期的轧辊磨损,轧辊磨损计算值与采用高精度磨床测量值吻合较好,表明该磨损模型具有较高的在线预报精度。
(5)以轧制过程轧辊轴向力最小为目标函数,考虑轧制过程中轧辊横移范围、轧辊等效凸度范围、带钢宽度范围及带钢跑偏范围优化设计了三次CVC辊型曲线。并与采用基本设计方法得到的三次CVC辊型曲线及SmartCrown曲线进行了比较,结果表明：采用优化设计得到的三次CVC辊型曲线,不仅可以满足带钢的控制要求,还可获得较小的轴向力。
(6)根据各个机架弯辊力范围及带钢出口凸度的控制能力,以保证带钢出口平直度良好及辊间压力均匀化为目标,合理地设计了精轧机组工作辊及支撑辊辊型曲线。现场实际应用结果表明,采用本文所设计辊型曲线,不仅可以满足热轧带钢不同轧制规程的要求,而且降低了工作辊与支撑辊端部接触应力值,减少了支撑辊边裂及剥落现象的发生,延长了支撑辊使用寿命。
High-quality automatic shape control is a goal which the hot rolling producers continusly pursues since long ago. Based on the international cooperation project of Kerea POSCO and RAL, Northeastern University,-"Development of CVC Roll Model and Thermal Crown Model for Hot Strip Mill", the project of BenSteel and RAL-"Research on improving strip shape control precision for BenSteel 1700mm HSM(Hot Strip Mill)", the project of GangLu and RAL-"Development of strip shape control system for GangLu 1250mm HSM", the basic theory and technology of strip shape control, optimization design and optimal allocation of roll shpe for HSM were researched by the numbers. The main works were shown as following:
(1) The strip shape set up system for HSM was established. The control strategy of strip shape for HSM was analyzed at length. The strip entry crown was calculated to obtain strip target crown and keep strip shape well, the coordinating relationship of strip between the adjacent stand was considered.Calculation model of roll gap under load, roll shift location and roll bending force were built.The roll shift location and roll bending force were calculated. Deviation of strip crown and flatness of a rolling schedule was measured.
(2) The mathematical models of roll system elastic deformation were set up with influence function method. The influence function of CVC roll bending force, roll elastic deformation, flattening between rolls and work roll flattening arised from the force were deduced. The equations of force balance, the relation between force and displacement and the deformation compatibility were obtained. The method to dispose of smoothed exponential and convergence index were bought forward, which solves effectively the calculation precision and the convergence problem of roll system elastic deformation.
(3) The axial symmetry models of roll temperature field were built with FDM (Finite Difference Method). Roll surface temperature and roll expansion calculated by the models were good agreement with the measurements. The results show that models of roll temperature field and thermal crown have high accuracy.
(4) The roll wear model was built with "slice method" and the roll shift location was considerd. Roll wear curves calculated by program were good agreement with the wear curves got by high-precision grinder. The results show that the roll wear model has high accuracy and should be applied in on-line prediction.
(5) Take the minimal axial force as target function, the cubic CVC roll shape curve was designed and the range of roll shift location, roll equivalent crown, strip width and strip deviaton were considered. The comparison of optimization CVC roll shape, basic CVC roll shape and SmartCrown roll shape shows that the strip crown control requirement was satisfied and the minimal roll axial force could be got by optimization CVC roll shape.
(6) Take the strip flatness in well and the uniform roll intermediate press as target, work roll shape was designed properly and the limit of roll bending force and strip crown at exit on each stand were considered. The application in production show that roll shape could satisfy different rolling schedule. The phenomenon of crack and flaking at end of backup roll occured for stress concentration was reduced and backup roll life was extended.
(1)建立了热连轧机板形控制设定系统。.详细地分析了热连轧带钢板形控制策略,以获得带钢出口目标凸度及板形良好为目标,考虑带钢在相邻机架间的协调关系,确定各机架带钢入口比例凸度。建立了负载条件下辊缝模型、轧辊横移位置及弯辊力计算模型。以某一换辊周期为例,计算了轧辊横移位置、弯辊力、并实测了带钢出口凸度及平直度偏差。
(2)采用影响函数法建立了辊系弹性变形数学模型,推导了CVC轧机工作辊弯辊力影响函数、轧辊弹性变形影响函数、工作辊压扁影响函数及辊间压扁影响函数,得出轧辊辊系弹性变形的力平衡方程、力—位移关系方程和变形协调方程。采用平滑指数和收敛指标取值的处理方法,有效地解决了辊系弹性变形计算精度及收敛问题。
(3)采用差分法建立了轴对称轧辊温度场模型。针对实际生产中某一换辊周期,用该模型求解的工作辊表面温度及热膨胀值与实测值吻合较好,验证了模型的实用性。
(4)采用“切片法”,同时考虑轧制过程中轧辊横移的影响,建立了轧辊磨损模型。计算了实际生产中某一换辊周期的轧辊磨损,轧辊磨损计算值与采用高精度磨床测量值吻合较好,表明该磨损模型具有较高的在线预报精度。
(5)以轧制过程轧辊轴向力最小为目标函数,考虑轧制过程中轧辊横移范围、轧辊等效凸度范围、带钢宽度范围及带钢跑偏范围优化设计了三次CVC辊型曲线。并与采用基本设计方法得到的三次CVC辊型曲线及SmartCrown曲线进行了比较,结果表明：采用优化设计得到的三次CVC辊型曲线,不仅可以满足带钢的控制要求,还可获得较小的轴向力。
(6)根据各个机架弯辊力范围及带钢出口凸度的控制能力,以保证带钢出口平直度良好及辊间压力均匀化为目标,合理地设计了精轧机组工作辊及支撑辊辊型曲线。现场实际应用结果表明,采用本文所设计辊型曲线,不仅可以满足热轧带钢不同轧制规程的要求,而且降低了工作辊与支撑辊端部接触应力值,减少了支撑辊边裂及剥落现象的发生,延长了支撑辊使用寿命。
High-quality automatic shape control is a goal which the hot rolling producers continusly pursues since long ago. Based on the international cooperation project of Kerea POSCO and RAL, Northeastern University,-"Development of CVC Roll Model and Thermal Crown Model for Hot Strip Mill", the project of BenSteel and RAL-"Research on improving strip shape control precision for BenSteel 1700mm HSM(Hot Strip Mill)", the project of GangLu and RAL-"Development of strip shape control system for GangLu 1250mm HSM", the basic theory and technology of strip shape control, optimization design and optimal allocation of roll shpe for HSM were researched by the numbers. The main works were shown as following:
(1) The strip shape set up system for HSM was established. The control strategy of strip shape for HSM was analyzed at length. The strip entry crown was calculated to obtain strip target crown and keep strip shape well, the coordinating relationship of strip between the adjacent stand was considered.Calculation model of roll gap under load, roll shift location and roll bending force were built.The roll shift location and roll bending force were calculated. Deviation of strip crown and flatness of a rolling schedule was measured.
(2) The mathematical models of roll system elastic deformation were set up with influence function method. The influence function of CVC roll bending force, roll elastic deformation, flattening between rolls and work roll flattening arised from the force were deduced. The equations of force balance, the relation between force and displacement and the deformation compatibility were obtained. The method to dispose of smoothed exponential and convergence index were bought forward, which solves effectively the calculation precision and the convergence problem of roll system elastic deformation.
(3) The axial symmetry models of roll temperature field were built with FDM (Finite Difference Method). Roll surface temperature and roll expansion calculated by the models were good agreement with the measurements. The results show that models of roll temperature field and thermal crown have high accuracy.
(4) The roll wear model was built with "slice method" and the roll shift location was considerd. Roll wear curves calculated by program were good agreement with the wear curves got by high-precision grinder. The results show that the roll wear model has high accuracy and should be applied in on-line prediction.
(5) Take the minimal axial force as target function, the cubic CVC roll shape curve was designed and the range of roll shift location, roll equivalent crown, strip width and strip deviaton were considered. The comparison of optimization CVC roll shape, basic CVC roll shape and SmartCrown roll shape shows that the strip crown control requirement was satisfied and the minimal roll axial force could be got by optimization CVC roll shape.
(6) Take the strip flatness in well and the uniform roll intermediate press as target, work roll shape was designed properly and the limit of roll bending force and strip crown at exit on each stand were considered. The application in production show that roll shape could satisfy different rolling schedule. The phenomenon of crack and flaking at end of backup roll occured for stress concentration was reduced and backup roll life was extended.
引文
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