新型高速连铸结晶器的理论研究与实际应用
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摘要
高速连铸的关键技术是使高温钢液在通过结晶器内腔的很短时间内形成一层均匀且有一定厚度和强度的坯壳,以抵抗钢液静压力,防止发生漏钢事故。锥度曲线设计是结晶器设计的核心内容,高速连铸结晶器的本质特征是具有优化的连续锥度曲线。但因工作条件恶劣,影响因素众多,目前尚未见到定量的包含诸主要影响因素的结晶器锥度曲线的设计计算公式,锥度曲线设计主要是采用边试验,边设计,边改进的方法进行。因此,对高速连铸结晶器锥度曲线生成机理的研究,具有重要的理论和实际意义。
本文把铸坯凝固传热的控制微分方程分为两类——固体导热微分方程和一组守恒方程,详细讨论了两类控制方程在求解结晶器内铸坯凝固传热过程中的特点和应用,建立了铸坯凝固传热热焓形式的温度控制微分方程和变间距有限差分方程。把铸坯与结晶器界面间的传热边界条件式分为两种——给定界面热流形式和给定界面传热系数形式,详细研究了两种传热边界条件式的特点以及相关的铸坯凝固传热计算的简化问题。本文还建立了结晶器内坯壳变形的蠕变力学模型和结晶器铜管变形的热弹性力学模型。
本文系统深入地研究了方坯、圆坯和矩形坯结晶器内壁的理想纵断面曲线和内腔的理想锥度曲线的生成机理,建立了新型高速连铸方坯、圆坯和矩形坯结晶器内壁的理想纵断面曲线和内腔的理想锥度曲线的设计计算公式。这些公式明确且定量地反映了浇铸钢种、拉坯速度和冷却条件等因素对结晶器锥度设计的影响,而且形式简单,便于应用。本文还详细研究了高速连铸结晶器铜管内角部结构的设计,建立了角部锥度小于中部锥度结晶器的内角部结构的设计计算公式。
以浇铸Q195钢种的154.5 mm×152.5 mm方坯结晶器为例,采用本文建立的模型和有限元法计算了结晶器内铸坯的温度场和变形量、结晶器铜管的温度场和变形量。通过将给定界面传热系数形式的传热边界条件式转换成给定界面热流形式的传热边界条件式,避免了温度场和应力场的耦合计算,简化了计算过程。用本文建立的新型高速连铸结晶器内壁的理想纵断面曲线和内腔的理想锥度曲线的设计计算公式,设计了结晶器铜管内壁的纵断面曲线和内腔的锥度曲线。
研究设计的浇铸154.5 mm×152.5 mm方坯的新型结晶器铜管自2005年4月起至今一直在唐山钢铁公司第2炼钢厂3号连铸机使用。浇铸的钢种包括普碳钢、硬线钢和低合金钢。拉坯速度v =2.2~2.6m/min,在低温“赶钢”时,最大拉坯速度曾达到3.3m/min。铸坯表面质量良好,单根铜管的平均过钢量为3700吨。
The key technology of the high speed continuous casting is that the uniform solidified shell with enough thickness and intensity was formed to support the ferrous pressure and prevent breakthrough, during the elevated-temperature melting steel passing through the cavity of mold in a very short time. The vital part of the mold design is the mold taper curve design. The substantial characteristic of the high speed continuous casting mold is its optimized continuous taper curve. However, the design and calculation formula for the mold taper curve design, involving the various influencing factors, has not been established quantificationally, because of the unfavorable working conditions and the various influencing factors. The design of the mold taper curve has been limited to the experiment-design-improvement process. Therefore, the investigation on the forming mechanism of the taper curve for the high speed continuous casting mold is very important in theory and practicality.
In the paper, the control difference equations of the solidification heat transfer process in continuous casting mold were differentiated into two types, one is the three-dimensional heat transfer difference equation, and the other is a set of conversation equations. The characteristics and their applications of these two types of control difference equations were discussed in detail. Both the temperature control difference equation of the solidification heat transfer process in continuous casting mold written with enthalpy form and the finite difference equations for alterable grid spaces were built. The thermal boundary conditions on the interface between the billet and the mold were differentiated into two types, one is the form of mold heat transfer flow on the interface, and the other is the form of mold heat transfer coefficients on the interface. The characteristics of the two types of thermal boundary conditions and the simplification calculation correlating the two types of thermal boundary conditions were studied in detail. The creep mechanical model of the solidified shell deformation in mold and the heat elastic mechanical model of the mold cupper tube deformation were built too.
The forming mechanisms of the optimal longitudinal profile curves on the inside wall and the optimal taper curves for inside cavity of the square billet mold, the round billet mold and rectangular billet mold were studied thoroughly. The design and the calculation formula of the optimal longitudinal profile curves on the inside wall and the optimal taper curves for inside cavity of the square billet mold, the round billet mold and rectangular billet mold for high speed continuous casting were obtained. The formula with the performance of simpleness and convenience, show quantificationally the effects of composition of steel, casting speed and cooling condition etc. on the design of the mold taper curve. The optimal design of the inside corner configuration of the high speed continuous casting mold was studied in detail too. The design and the calculation formula of the inside corner configuration for the mold whose corner taper is smaller than middle taper were obtained.
The square billet mold for casting Q195 steel with the dimension of 154.5 mm×152.5 mm was illustrated. Using of the model developed in this paper and the finite element method, the temperature fields and deformation fields of the billet and the mold cupper tube were calculated. By means of translating the thermal boundary condition on the interface between the billet and the mold from the form of heat transfer coefficient into the form of heat transfer flow, coupling calculation between the temperature field and stress field was avoided. Using of the design and calculation formula for the optimal longitudinal profile curve and the optimal taper curve of the high speed continuous casting mold, the longitudinal profile curve and the taper curve of the mold copper tube were designed.
The new type square billet mold for casting 154.5 mm×152.5 mm square billet has being used since April 2005 on continuous caster 3 in Tangshan Iron and Steel Co. Ltd.. The steels poured involved plain carbon steel, hard string steel and steel holding little alloy. The casting speed was v =2.2~2.6m/min. The maximal casting speed was up to v =3.3m/minaccidentally when the molten steel temperature was very low. There was no obvious oscillation mark on the billet surface. The average steel production of a copper tube was 3700 ton.
本文把铸坯凝固传热的控制微分方程分为两类——固体导热微分方程和一组守恒方程,详细讨论了两类控制方程在求解结晶器内铸坯凝固传热过程中的特点和应用,建立了铸坯凝固传热热焓形式的温度控制微分方程和变间距有限差分方程。把铸坯与结晶器界面间的传热边界条件式分为两种——给定界面热流形式和给定界面传热系数形式,详细研究了两种传热边界条件式的特点以及相关的铸坯凝固传热计算的简化问题。本文还建立了结晶器内坯壳变形的蠕变力学模型和结晶器铜管变形的热弹性力学模型。
本文系统深入地研究了方坯、圆坯和矩形坯结晶器内壁的理想纵断面曲线和内腔的理想锥度曲线的生成机理,建立了新型高速连铸方坯、圆坯和矩形坯结晶器内壁的理想纵断面曲线和内腔的理想锥度曲线的设计计算公式。这些公式明确且定量地反映了浇铸钢种、拉坯速度和冷却条件等因素对结晶器锥度设计的影响,而且形式简单,便于应用。本文还详细研究了高速连铸结晶器铜管内角部结构的设计,建立了角部锥度小于中部锥度结晶器的内角部结构的设计计算公式。
以浇铸Q195钢种的154.5 mm×152.5 mm方坯结晶器为例,采用本文建立的模型和有限元法计算了结晶器内铸坯的温度场和变形量、结晶器铜管的温度场和变形量。通过将给定界面传热系数形式的传热边界条件式转换成给定界面热流形式的传热边界条件式,避免了温度场和应力场的耦合计算,简化了计算过程。用本文建立的新型高速连铸结晶器内壁的理想纵断面曲线和内腔的理想锥度曲线的设计计算公式,设计了结晶器铜管内壁的纵断面曲线和内腔的锥度曲线。
研究设计的浇铸154.5 mm×152.5 mm方坯的新型结晶器铜管自2005年4月起至今一直在唐山钢铁公司第2炼钢厂3号连铸机使用。浇铸的钢种包括普碳钢、硬线钢和低合金钢。拉坯速度v =2.2~2.6m/min,在低温“赶钢”时,最大拉坯速度曾达到3.3m/min。铸坯表面质量良好,单根铜管的平均过钢量为3700吨。
The key technology of the high speed continuous casting is that the uniform solidified shell with enough thickness and intensity was formed to support the ferrous pressure and prevent breakthrough, during the elevated-temperature melting steel passing through the cavity of mold in a very short time. The vital part of the mold design is the mold taper curve design. The substantial characteristic of the high speed continuous casting mold is its optimized continuous taper curve. However, the design and calculation formula for the mold taper curve design, involving the various influencing factors, has not been established quantificationally, because of the unfavorable working conditions and the various influencing factors. The design of the mold taper curve has been limited to the experiment-design-improvement process. Therefore, the investigation on the forming mechanism of the taper curve for the high speed continuous casting mold is very important in theory and practicality.
In the paper, the control difference equations of the solidification heat transfer process in continuous casting mold were differentiated into two types, one is the three-dimensional heat transfer difference equation, and the other is a set of conversation equations. The characteristics and their applications of these two types of control difference equations were discussed in detail. Both the temperature control difference equation of the solidification heat transfer process in continuous casting mold written with enthalpy form and the finite difference equations for alterable grid spaces were built. The thermal boundary conditions on the interface between the billet and the mold were differentiated into two types, one is the form of mold heat transfer flow on the interface, and the other is the form of mold heat transfer coefficients on the interface. The characteristics of the two types of thermal boundary conditions and the simplification calculation correlating the two types of thermal boundary conditions were studied in detail. The creep mechanical model of the solidified shell deformation in mold and the heat elastic mechanical model of the mold cupper tube deformation were built too.
The forming mechanisms of the optimal longitudinal profile curves on the inside wall and the optimal taper curves for inside cavity of the square billet mold, the round billet mold and rectangular billet mold were studied thoroughly. The design and the calculation formula of the optimal longitudinal profile curves on the inside wall and the optimal taper curves for inside cavity of the square billet mold, the round billet mold and rectangular billet mold for high speed continuous casting were obtained. The formula with the performance of simpleness and convenience, show quantificationally the effects of composition of steel, casting speed and cooling condition etc. on the design of the mold taper curve. The optimal design of the inside corner configuration of the high speed continuous casting mold was studied in detail too. The design and the calculation formula of the inside corner configuration for the mold whose corner taper is smaller than middle taper were obtained.
The square billet mold for casting Q195 steel with the dimension of 154.5 mm×152.5 mm was illustrated. Using of the model developed in this paper and the finite element method, the temperature fields and deformation fields of the billet and the mold cupper tube were calculated. By means of translating the thermal boundary condition on the interface between the billet and the mold from the form of heat transfer coefficient into the form of heat transfer flow, coupling calculation between the temperature field and stress field was avoided. Using of the design and calculation formula for the optimal longitudinal profile curve and the optimal taper curve of the high speed continuous casting mold, the longitudinal profile curve and the taper curve of the mold copper tube were designed.
The new type square billet mold for casting 154.5 mm×152.5 mm square billet has being used since April 2005 on continuous caster 3 in Tangshan Iron and Steel Co. Ltd.. The steels poured involved plain carbon steel, hard string steel and steel holding little alloy. The casting speed was v =2.2~2.6m/min. The maximal casting speed was up to v =3.3m/minaccidentally when the molten steel temperature was very low. There was no obvious oscillation mark on the billet surface. The average steel production of a copper tube was 3700 ton.
引文
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