高性能大锻件控形控性规律与操作机—压机联动轨迹的研究
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摘要
大锻件是冶金、造船、石油化工、电力、核能、航空航天和国防军工等领域的大型成套设备的关键零部件,苛刻的服役条件决定了其高质量要求。大锻件的成形制造一般以大型铸锭为原材料,由于大型铸锭通常存在严重的晶粒粗大、夹杂、偏析、疏松和空洞等冶金缺陷,因此锻造的主要目的是成形和成性,即在保证成形精度的同时,打碎枝晶、细化晶粒、消除偏析、压实疏松和焊合空洞,尽可能消除大型铸锭的冶金缺陷。本文针对我国大锻件锻造技术水平较低和生产能力不足的现状,以实现高性能大锻件的自动化锻造为目的,研究了大锻件的控形控性规律,提出了锻造操作机与压机联动轨迹的规划方法。主要包括以下内容。
采用热模拟实验,研究了典型大锻件用材料42CrMo钢的高温流变行为,建立了应变-应变速率补偿的Arrhenius型高温流变本构方程,可精确预测其高温流变应力,其预测值和实验值的最大相对误差及其标准偏差分别仅为-4.36%和2.36%。
采用热模拟实验与金相观察,研究了典型大锻件用材料42CrMo钢的动态再结晶、静态再结晶、亚动态再结晶与晶粒长大行为。基于实验结果,建立了三种再结晶的动力学模型与晶粒尺寸模型。结果表明：(1)减小初始奥氏体晶粒尺寸,动态与静态再结晶速率增快、晶粒变细。亚动态再结晶晶粒则在初始奥氏体晶粒尺寸较小时也变细,而在初始奥氏体晶粒较大时变化不明显；(2)升高变形温度,动态、静态与亚动态再结晶速率均增快、晶粒均粗化；(3)增大应变速率,动态、静态与亚动态再结晶晶粒均细化；(4)增大变形量,动态再结晶分数增大、静态再结晶速率增快且晶粒尺寸变小；(5)奥氏体晶粒长大速率受保温温度影响较大,受保温时间影响较小；(6)三种再结晶模型的预测结果均与实验结果吻合较好。
采用细观损伤力学的研究方法,建立了研究理想刚粘塑性大锻件内部椭圆柱形(圆柱形)空洞演变的代表性体元模型；基于变分原理,导出了体元基体材料速度场的泛函；采用瑞利-里兹法对泛函变分问题进行求解,获得了不同远场应力条件下的空洞演变规律。结果表明：(1)在远场纯剪应力作用下,空洞的形状系数变化率与其形状系数、材料Norton指数分别满足抛物线函数、一次指数函数关系；(2)在远场单向压应力作用下,空洞的形状系数变化率与其形状系数、材料Norton指数分别满足线性函数、一次指数函数关系；(3)在远场双向压应力作用下,空洞的形状系数变化率与其形状系数满足抛物线函数关系、且抛物线的顶点、张口与应力三轴度、材料Norton指数有关；(4)在远场单向压应力作用下,空洞的取向变化率与空洞形状、取向及材料Norton指数有关。
采用热力耦合的三维有限元模型,研究了大锻件内部椭球形(球形)空洞的演变机理；为了综合考虑应力、应变对空洞形状演变的影响,提出了一个新的特征参量——空洞形状估计参数,并建立了空洞形状估计参数与形状系数的关联模型；获得了平砧拔长工艺参数对大锻件内部空洞形状演变的影响规律,并通过实验验证了本文有限元模型的正确性。
集成了本文获得的大锻件控形控性规律,提出了锻造操作机与压机联动轨迹的规划方法,开发了操作机与压机联动轨迹的规划系统,并制定了操作机与压机联动轨迹的合理性评价准则,为操作装备的功能设计和控制提供理论依据。结合300MW发电机转子锻件的平砧拔长工艺,给出了操作机-压机联动轨迹规划系统的工程应用实例。
Large forgings are the key parts for heavy machines and equipments which are widely used in metallurgy, ship-building, petrochemical engineering, power generation, and nuclear power industries. Due to the extreme service conditions, the quality of large forgings becomes more and more important. However, the defects, such as coarse grains, slag inclusions, heating cracks, segregations, porosities and voids, inevitably appear when the steel ingots are casted. The mian goals of hot forging are to eliminate metallurgy defects inside large ingots, including breaking dendrites, refining grains, eliminating segregations, compacting porosities, closing voids, and so on. In this dissertation, the flow behaviors, void and microstructure evolution of a typical material for large forgings are investigated. The methods to plan and optimize linkage trajectory of the manipulator-press are put forwarded. The main contents of this dissertation are shown as following.
The flow behaviors of42CrMo steel are investigated by on one-pass hot compression tests. Based on experimental results, a revised model describing the relationships of the flow stress, strain rate and forming temperature of42CrMo steel at elevated temperatures is proposed by the compensation of strain and strain rate. The stress-strain values of42CrMo steel predicted by the proposed model well agree with experimental results. The errors and the standard deviation between the preicted and experimental stress is only-4.36%and2.36%.
The dynamic, static and metadynamic recrystallization behaviors of42CrMo steel are investigated by hot compression and metallographic tests. Based on the experimental results, the kinetic models and grain size models of three kinds of recrystallization phenomena for42CrMo steel are proposed. Results show that:(1) When the initial austenitic grain size is decreased, both the dynamic and static recrystallization will easily occur, and then the dynamic and static recrystallization grain sizes will decrease. Also, decreasing the initial austenitic grain size will result in the fine metadynamic recrystallization grain size;(2) With the increase of the deformation temperature, the rate of dynamic, static and metadynamic recrystalli-zation will become fast, and the coarse grain size appear;(3) With the increase of strain rate, the dynamic, static and metadynamic recrystallization grain sizes become fine;(4) With the increase of deformation degree, the dynamic recrystallization fraction increases, and the dynamic and static recrystallization grain sizes become more fine;(5) The effects of holding temperature on the grain growth are significant. However, the effects of the holding time on the grain growth are slight;(6) The predictions of the kinetic models and grain size models for three kinds of recrystallization phenomena are well in agreement with the experimental results.
Based on the mesoscopic damage mechanics, the representative volume element (RVE) model for elliptic cylinder void (include cylindrical void) inside large viscous mateial forgings is put forward. The variational functions for the soluting the local velocity field are deduced. The laws for void evolution at different remote stress fields were obtained. Results show that:(1) For the remote shear stress field, the relationships between the changing rate of void aspect ratio and void aspect ratio, material Norton exponent can be represented as the parabolic function and first order exponential function, respectively;(2) For the remote uniaxial compression stress field, the relationships between the changing rate of void aspect ratio and void aspect ratio, material Norton exponent can be represented as the linear function and first order exponential function, respectively;(3) For the remote biaxial compression stress field, the relationships between the changing rate of void aspect ratio and void aspect ratio can be represented as the parabolic function;(4) For the remote uniaxial compression stress field, the changing rate of void orintation is relate to its aspect ratio, its orintation, and material Norton exponent.
The mechanism of spherical or spheroidal void evolution is studied by thermo-mechanical coupled finite element model. A void aspect ratio evaluation index is proposed to consider the effects of stress and strain on the evolution of the void aspect ratio. The model between the void aspect ratio evaluation index and the void aspect ratio is established. Then, the effects of stretching processing parameters on the void aspect ratio evaluation index are studied, and the predicted results from FEM are verified by the experments.
By integrating laws for high quality large forgings abtained in this dissertation, the methods to plan linkage trajectory of manipulator-press is put forward, and the modules for producing the linkage trajectory of manipulator-press is developed. Also, the judging rules for the linkage trajectory are established. Taking the strecthing process of300MW generator as an example, the industrial application of the modules to produce the linkage trajectory of manipulator-press is given.
采用热模拟实验,研究了典型大锻件用材料42CrMo钢的高温流变行为,建立了应变-应变速率补偿的Arrhenius型高温流变本构方程,可精确预测其高温流变应力,其预测值和实验值的最大相对误差及其标准偏差分别仅为-4.36%和2.36%。
采用热模拟实验与金相观察,研究了典型大锻件用材料42CrMo钢的动态再结晶、静态再结晶、亚动态再结晶与晶粒长大行为。基于实验结果,建立了三种再结晶的动力学模型与晶粒尺寸模型。结果表明：(1)减小初始奥氏体晶粒尺寸,动态与静态再结晶速率增快、晶粒变细。亚动态再结晶晶粒则在初始奥氏体晶粒尺寸较小时也变细,而在初始奥氏体晶粒较大时变化不明显；(2)升高变形温度,动态、静态与亚动态再结晶速率均增快、晶粒均粗化；(3)增大应变速率,动态、静态与亚动态再结晶晶粒均细化；(4)增大变形量,动态再结晶分数增大、静态再结晶速率增快且晶粒尺寸变小；(5)奥氏体晶粒长大速率受保温温度影响较大,受保温时间影响较小；(6)三种再结晶模型的预测结果均与实验结果吻合较好。
采用细观损伤力学的研究方法,建立了研究理想刚粘塑性大锻件内部椭圆柱形(圆柱形)空洞演变的代表性体元模型；基于变分原理,导出了体元基体材料速度场的泛函；采用瑞利-里兹法对泛函变分问题进行求解,获得了不同远场应力条件下的空洞演变规律。结果表明：(1)在远场纯剪应力作用下,空洞的形状系数变化率与其形状系数、材料Norton指数分别满足抛物线函数、一次指数函数关系；(2)在远场单向压应力作用下,空洞的形状系数变化率与其形状系数、材料Norton指数分别满足线性函数、一次指数函数关系；(3)在远场双向压应力作用下,空洞的形状系数变化率与其形状系数满足抛物线函数关系、且抛物线的顶点、张口与应力三轴度、材料Norton指数有关；(4)在远场单向压应力作用下,空洞的取向变化率与空洞形状、取向及材料Norton指数有关。
采用热力耦合的三维有限元模型,研究了大锻件内部椭球形(球形)空洞的演变机理；为了综合考虑应力、应变对空洞形状演变的影响,提出了一个新的特征参量——空洞形状估计参数,并建立了空洞形状估计参数与形状系数的关联模型；获得了平砧拔长工艺参数对大锻件内部空洞形状演变的影响规律,并通过实验验证了本文有限元模型的正确性。
集成了本文获得的大锻件控形控性规律,提出了锻造操作机与压机联动轨迹的规划方法,开发了操作机与压机联动轨迹的规划系统,并制定了操作机与压机联动轨迹的合理性评价准则,为操作装备的功能设计和控制提供理论依据。结合300MW发电机转子锻件的平砧拔长工艺,给出了操作机-压机联动轨迹规划系统的工程应用实例。
Large forgings are the key parts for heavy machines and equipments which are widely used in metallurgy, ship-building, petrochemical engineering, power generation, and nuclear power industries. Due to the extreme service conditions, the quality of large forgings becomes more and more important. However, the defects, such as coarse grains, slag inclusions, heating cracks, segregations, porosities and voids, inevitably appear when the steel ingots are casted. The mian goals of hot forging are to eliminate metallurgy defects inside large ingots, including breaking dendrites, refining grains, eliminating segregations, compacting porosities, closing voids, and so on. In this dissertation, the flow behaviors, void and microstructure evolution of a typical material for large forgings are investigated. The methods to plan and optimize linkage trajectory of the manipulator-press are put forwarded. The main contents of this dissertation are shown as following.
The flow behaviors of42CrMo steel are investigated by on one-pass hot compression tests. Based on experimental results, a revised model describing the relationships of the flow stress, strain rate and forming temperature of42CrMo steel at elevated temperatures is proposed by the compensation of strain and strain rate. The stress-strain values of42CrMo steel predicted by the proposed model well agree with experimental results. The errors and the standard deviation between the preicted and experimental stress is only-4.36%and2.36%.
The dynamic, static and metadynamic recrystallization behaviors of42CrMo steel are investigated by hot compression and metallographic tests. Based on the experimental results, the kinetic models and grain size models of three kinds of recrystallization phenomena for42CrMo steel are proposed. Results show that:(1) When the initial austenitic grain size is decreased, both the dynamic and static recrystallization will easily occur, and then the dynamic and static recrystallization grain sizes will decrease. Also, decreasing the initial austenitic grain size will result in the fine metadynamic recrystallization grain size;(2) With the increase of the deformation temperature, the rate of dynamic, static and metadynamic recrystalli-zation will become fast, and the coarse grain size appear;(3) With the increase of strain rate, the dynamic, static and metadynamic recrystallization grain sizes become fine;(4) With the increase of deformation degree, the dynamic recrystallization fraction increases, and the dynamic and static recrystallization grain sizes become more fine;(5) The effects of holding temperature on the grain growth are significant. However, the effects of the holding time on the grain growth are slight;(6) The predictions of the kinetic models and grain size models for three kinds of recrystallization phenomena are well in agreement with the experimental results.
Based on the mesoscopic damage mechanics, the representative volume element (RVE) model for elliptic cylinder void (include cylindrical void) inside large viscous mateial forgings is put forward. The variational functions for the soluting the local velocity field are deduced. The laws for void evolution at different remote stress fields were obtained. Results show that:(1) For the remote shear stress field, the relationships between the changing rate of void aspect ratio and void aspect ratio, material Norton exponent can be represented as the parabolic function and first order exponential function, respectively;(2) For the remote uniaxial compression stress field, the relationships between the changing rate of void aspect ratio and void aspect ratio, material Norton exponent can be represented as the linear function and first order exponential function, respectively;(3) For the remote biaxial compression stress field, the relationships between the changing rate of void aspect ratio and void aspect ratio can be represented as the parabolic function;(4) For the remote uniaxial compression stress field, the changing rate of void orintation is relate to its aspect ratio, its orintation, and material Norton exponent.
The mechanism of spherical or spheroidal void evolution is studied by thermo-mechanical coupled finite element model. A void aspect ratio evaluation index is proposed to consider the effects of stress and strain on the evolution of the void aspect ratio. The model between the void aspect ratio evaluation index and the void aspect ratio is established. Then, the effects of stretching processing parameters on the void aspect ratio evaluation index are studied, and the predicted results from FEM are verified by the experments.
By integrating laws for high quality large forgings abtained in this dissertation, the methods to plan linkage trajectory of manipulator-press is put forward, and the modules for producing the linkage trajectory of manipulator-press is developed. Also, the judging rules for the linkage trajectory are established. Taking the strecthing process of300MW generator as an example, the industrial application of the modules to produce the linkage trajectory of manipulator-press is given.
引文
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