大锻件锻造成形过程中内部空洞型缺陷演化规律的研究
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摘要
大锻件是大型成套设备的核心零部件,被广泛应用于电力、冶金、造船、石油化工、核能、航空航天和国防军工领域。大锻件通常工作条件差、载荷大、安全可靠性要求高,因此质量要求极为严格。然而,钢铁冶金过程决定了大型钢锭内部不可避免地会存在空洞型缺陷,内部空洞的存在破坏了金属的连续性,容易形成应力集中与裂纹损伤,导致锻件寿命缩短以致报废。因此,深入认识空洞演化规律,探索提高空洞压实效果的条件,将有助于提高锻件内在质量,促进锻造工艺的制定由经验走向科学。由于大锻件内部分散着大量相对极为微小的空洞型缺陷,为了全面解析空洞在锻造过程中的演变,本文对空洞型缺陷的演化进行了较为系统的研究,试图回答这样的问题:如果大锻件某位置存在空洞型缺陷,那么空洞演化与大锻件锻造过程中的宏观力学量场有何定量关系?空洞演化有何规律?为此,本文基于细观塑性理论,通过理论建模、数值模拟和试验研究,提出了通用的空洞闭合判定准则,开发了模拟空洞演化的计算程序,在DEFORM软件基础上建立了大锻件锻造过程中内部空洞演化的仿真平台,并通过试验验证了所提出的理论和方法的正确性。主要研究内容和成果如下:
针对大锻件锻造成形过程中内部大量微小空洞同时存在并各自变形的情况,本文提出了研究大锻件内部空洞演化的典型体元模型,典型体元模型是建立空洞演化与大锻件锻造成形工艺之间定量联系的桥梁。典型体元可以归结为大锻件宏观上的一个点元,对微小空洞而言可以视为无限大,典型体元的边界条件为大锻件锻造过程中该点处的宏观力学状态,典型体元内部的速度场决定空洞的演化。基于典型体元模型,运用细观塑性理论,建立了空洞的体积和形状演化参数与宏观力学量场之间的一般关系;基于虚功原理,建立了研究大锻件内部空洞演化的通用方法。典型体元模型为探索大锻件锻造过程中内部空洞型缺陷的演化规律提供了比较成功的研究方法。
由于大锻件锻造成形过程中内部空洞的体积和形状都会变化,为了得到空洞演化的定量规律,本文基于旋转椭球双曲坐标系和空洞周围基体材料的动可容速度场,采用Rayleigh-Ritz法,对空洞演化进行了详细的数值计算,提出用空洞相对体积(空洞当前体积与空洞初始体积的比)作为判断大锻件锻造成形过程中内部空洞演化的依据,得到了材料属性、应力和应变状态对空洞演化的影响规律。结果表明,空洞体积变形率随着应力三轴度水平和材料Norton指数的增大而单调增加;空洞相对体积随应力三轴度水平的提高和等效应变的增大而减小;随着应力三轴度水平和材料Norton指数的增大,空洞完全闭合所需的远场等效应变减小。
针对实际生产中对具有明确物理意义和普遍适用性的空洞闭合判定准则的现实需求,本文基于力学分析和数值计算,通过研究球形空洞演化成扁椭球并最终闭合成为裂纹的过程,得到了空洞闭合的插值模型。根据插值模型和空洞演化的数值计算结果,通过引入四个参数,提出了一个简明的空洞体积演化模型,得到了包含材料属性、应力应变状态和温度影响的具有明确物理意义的大锻件内部空洞闭合判定准则,其中温度的影响通过材料Norton指数和应力应变关系来体现。空洞闭合判定准则定量地反映了空洞闭合的一般规律。
针对大锻件锻造成形过程中难以准确预报内部大量微小空洞同时存在并各自演化这一难题,本文通过开发模拟空洞演化的计算程序,将空洞演化模型嵌入商用软件DEFORM,实现了大锻件锻造成形过程中内部空洞体积演变的定量化和可视化,建立了空洞演化的仿真平台,首次在大锻件锻造过程的模拟中将空洞相对体积同步、直观地显示出来,为锻造工艺的优化和锻造方法的创新提供了理论和计算依据,为揭示空洞演化规律和预报锻造工艺对空洞型缺陷的压实效果提供了一条新途径。在此仿真平台上,对不同砧形的镦粗工艺和多工步多道次的拔长工艺过程中锻件内部空洞闭合情况进行了数值模拟,分析对比了不同锻造方法对内部空洞的压实效果,并提出了钹形砧镦粗方法。
由于大锻件体积大、重量高、价格昂贵,直接用大锻件进行试验受到诸多限制,而铅是再结晶温度为室温的金属材料,其常温塑性性能与高温钢的塑性性能具有很好的相似性。本文通过在PbSb3铅块上加工空洞并组装成一个整体的方法,制备了可以定量研究空洞演化的试件,试验研究了不同锻造方法对空洞闭合的影响,并采用精密的光学投影仪对空洞体积进行测量,试验结果和数值模拟结果吻合较好,验证了本文建立的大锻件内部空洞演化模型与仿真方法的有效性和准确性。
利用本文建立的空洞演化仿真平台,分析了1000MW低压转子现行的锻造工艺,在对现行工艺进行定量评估的基础上,建议了新的锻造工艺。研究表明,基于空洞演化仿真平台,通过CAE分析和优化,可以为大锻件设计最优的锻造方法,安排更经济的成形工艺,获得更好的成形质量。
Large forgings, the key parts for heavy machine and equipment, are widely used in power generation, metallurgy, shipbuilding, petrochemical engineering, nuclear power, aerospace and defense industry. The quality requirements of large forgings are extremely strict because large loads, poor working conditions, high safety and reliability requirements are its fundamental characteristics. However, internal defects such as shrinkage cavities and porosity inevitably occur in large ingots during steel casting. The continuity of the metal is destroyed by these internal voids and stress concentration and crack damage are easy to form, resulting in loss of life and discarding. Therefore, understanding of void evolution, exploration of the condition for void closure, and design of forging process to improve the forging quality, are of great theoretical significance and practical value. In this paper, on the basis of theoretical modeling, numerical simulation and experimental study, void evolution in large ingot during hot forging is investigated systemically, which yields the following main achievements:
Based on mesomechanic plastic theory and the characteristics of large forgings, the representative volume element (RVE) model for void evolution in large ingot during hot forging is put forward, and the relationships between void volume and shape evolution and macroscopic field variables are established. Based on the principle of virtual work, the variational functional for the solution of the local velocity field is derived, and a general method for investigating void evolution is established. The RVE model is a successful solution for studying void evolution in large ingot with a large number of small void and respective deformations during hot forging.
Through the calculation for void evolution, the relative void volume (the ratio of current void volume to initial void volume) is suggested as the indicator for void evolution in large ingot during hot forging, and effects of the material properties, stress and strain state on void evolution are revealed. The results show that, the volumetric strain-rate of the void increases monotonically with increasing stress triaxiality level and Norton exponent of the material; relative void volume decreases as the stress triaxiality level and effective strain increase; the remote effective strain required for void closure decreases as the stress triaxiality level and Norton exponent increase.
Based on the numerical results and the interpolation model, a criterion for void closure, which takes the material property, stress and strain state, and temperature into account, is proposed. The effect of temperature is considered in the Norton exponent and the stress-strain relationship. The criterion has a clear physical meaning and a general applicability for large ingot during hot forging.
By developing the key simulation program for void evolution, the simulation platform for void evolution is established based on the commercial software DEFORM, and for the first time the relative void volume is displayed clearly and synchronously in the simulation of the hot forging process for large ingot. It provides a new approach for selection and evaluation of the traditional forging processes, and a convenient and powerful tool for optimization of forging processes and innovation of forging methods. Based on the established simulation platform for the void evolution, numerical simulations for upsetting processes with different dies and for stretching processes with multi-stroke and multi-pass forging are performed, the effects of different processes on void closure are analyzed and compared, and the cymbal-shaped die upsetting process is proposed.
A new experimental method is presented for quantitative investigation of the void evolution. Effects of different forging processes on void closure are investigated. The sophisticated optical projector is adopted in the measurement of the size and volume of the void to ensure the accuracy of the test results. Good agreements of the predicted results with the measured ones confirm the validity of the void evolution model, the void closure criterion, and the simulation platform for void evolution in large ingot during hot forging.
Using the established simulation platform for void evolution, forging processes of 1000MW low-pressure rotor is analyzed and evaluated, and new forging processes are recommended by applying the cymbal-shaped die in the upsetting processes. It shows that, based on the simulation platform for void evolution, the optimum forging method can be designed, the most economical forging process can be arranged and the best forging quality can be achieved through the CAE analysis and optimization.
针对大锻件锻造成形过程中内部大量微小空洞同时存在并各自变形的情况,本文提出了研究大锻件内部空洞演化的典型体元模型,典型体元模型是建立空洞演化与大锻件锻造成形工艺之间定量联系的桥梁。典型体元可以归结为大锻件宏观上的一个点元,对微小空洞而言可以视为无限大,典型体元的边界条件为大锻件锻造过程中该点处的宏观力学状态,典型体元内部的速度场决定空洞的演化。基于典型体元模型,运用细观塑性理论,建立了空洞的体积和形状演化参数与宏观力学量场之间的一般关系;基于虚功原理,建立了研究大锻件内部空洞演化的通用方法。典型体元模型为探索大锻件锻造过程中内部空洞型缺陷的演化规律提供了比较成功的研究方法。
由于大锻件锻造成形过程中内部空洞的体积和形状都会变化,为了得到空洞演化的定量规律,本文基于旋转椭球双曲坐标系和空洞周围基体材料的动可容速度场,采用Rayleigh-Ritz法,对空洞演化进行了详细的数值计算,提出用空洞相对体积(空洞当前体积与空洞初始体积的比)作为判断大锻件锻造成形过程中内部空洞演化的依据,得到了材料属性、应力和应变状态对空洞演化的影响规律。结果表明,空洞体积变形率随着应力三轴度水平和材料Norton指数的增大而单调增加;空洞相对体积随应力三轴度水平的提高和等效应变的增大而减小;随着应力三轴度水平和材料Norton指数的增大,空洞完全闭合所需的远场等效应变减小。
针对实际生产中对具有明确物理意义和普遍适用性的空洞闭合判定准则的现实需求,本文基于力学分析和数值计算,通过研究球形空洞演化成扁椭球并最终闭合成为裂纹的过程,得到了空洞闭合的插值模型。根据插值模型和空洞演化的数值计算结果,通过引入四个参数,提出了一个简明的空洞体积演化模型,得到了包含材料属性、应力应变状态和温度影响的具有明确物理意义的大锻件内部空洞闭合判定准则,其中温度的影响通过材料Norton指数和应力应变关系来体现。空洞闭合判定准则定量地反映了空洞闭合的一般规律。
针对大锻件锻造成形过程中难以准确预报内部大量微小空洞同时存在并各自演化这一难题,本文通过开发模拟空洞演化的计算程序,将空洞演化模型嵌入商用软件DEFORM,实现了大锻件锻造成形过程中内部空洞体积演变的定量化和可视化,建立了空洞演化的仿真平台,首次在大锻件锻造过程的模拟中将空洞相对体积同步、直观地显示出来,为锻造工艺的优化和锻造方法的创新提供了理论和计算依据,为揭示空洞演化规律和预报锻造工艺对空洞型缺陷的压实效果提供了一条新途径。在此仿真平台上,对不同砧形的镦粗工艺和多工步多道次的拔长工艺过程中锻件内部空洞闭合情况进行了数值模拟,分析对比了不同锻造方法对内部空洞的压实效果,并提出了钹形砧镦粗方法。
由于大锻件体积大、重量高、价格昂贵,直接用大锻件进行试验受到诸多限制,而铅是再结晶温度为室温的金属材料,其常温塑性性能与高温钢的塑性性能具有很好的相似性。本文通过在PbSb3铅块上加工空洞并组装成一个整体的方法,制备了可以定量研究空洞演化的试件,试验研究了不同锻造方法对空洞闭合的影响,并采用精密的光学投影仪对空洞体积进行测量,试验结果和数值模拟结果吻合较好,验证了本文建立的大锻件内部空洞演化模型与仿真方法的有效性和准确性。
利用本文建立的空洞演化仿真平台,分析了1000MW低压转子现行的锻造工艺,在对现行工艺进行定量评估的基础上,建议了新的锻造工艺。研究表明,基于空洞演化仿真平台,通过CAE分析和优化,可以为大锻件设计最优的锻造方法,安排更经济的成形工艺,获得更好的成形质量。
Large forgings, the key parts for heavy machine and equipment, are widely used in power generation, metallurgy, shipbuilding, petrochemical engineering, nuclear power, aerospace and defense industry. The quality requirements of large forgings are extremely strict because large loads, poor working conditions, high safety and reliability requirements are its fundamental characteristics. However, internal defects such as shrinkage cavities and porosity inevitably occur in large ingots during steel casting. The continuity of the metal is destroyed by these internal voids and stress concentration and crack damage are easy to form, resulting in loss of life and discarding. Therefore, understanding of void evolution, exploration of the condition for void closure, and design of forging process to improve the forging quality, are of great theoretical significance and practical value. In this paper, on the basis of theoretical modeling, numerical simulation and experimental study, void evolution in large ingot during hot forging is investigated systemically, which yields the following main achievements:
Based on mesomechanic plastic theory and the characteristics of large forgings, the representative volume element (RVE) model for void evolution in large ingot during hot forging is put forward, and the relationships between void volume and shape evolution and macroscopic field variables are established. Based on the principle of virtual work, the variational functional for the solution of the local velocity field is derived, and a general method for investigating void evolution is established. The RVE model is a successful solution for studying void evolution in large ingot with a large number of small void and respective deformations during hot forging.
Through the calculation for void evolution, the relative void volume (the ratio of current void volume to initial void volume) is suggested as the indicator for void evolution in large ingot during hot forging, and effects of the material properties, stress and strain state on void evolution are revealed. The results show that, the volumetric strain-rate of the void increases monotonically with increasing stress triaxiality level and Norton exponent of the material; relative void volume decreases as the stress triaxiality level and effective strain increase; the remote effective strain required for void closure decreases as the stress triaxiality level and Norton exponent increase.
Based on the numerical results and the interpolation model, a criterion for void closure, which takes the material property, stress and strain state, and temperature into account, is proposed. The effect of temperature is considered in the Norton exponent and the stress-strain relationship. The criterion has a clear physical meaning and a general applicability for large ingot during hot forging.
By developing the key simulation program for void evolution, the simulation platform for void evolution is established based on the commercial software DEFORM, and for the first time the relative void volume is displayed clearly and synchronously in the simulation of the hot forging process for large ingot. It provides a new approach for selection and evaluation of the traditional forging processes, and a convenient and powerful tool for optimization of forging processes and innovation of forging methods. Based on the established simulation platform for the void evolution, numerical simulations for upsetting processes with different dies and for stretching processes with multi-stroke and multi-pass forging are performed, the effects of different processes on void closure are analyzed and compared, and the cymbal-shaped die upsetting process is proposed.
A new experimental method is presented for quantitative investigation of the void evolution. Effects of different forging processes on void closure are investigated. The sophisticated optical projector is adopted in the measurement of the size and volume of the void to ensure the accuracy of the test results. Good agreements of the predicted results with the measured ones confirm the validity of the void evolution model, the void closure criterion, and the simulation platform for void evolution in large ingot during hot forging.
Using the established simulation platform for void evolution, forging processes of 1000MW low-pressure rotor is analyzed and evaluated, and new forging processes are recommended by applying the cymbal-shaped die in the upsetting processes. It shows that, based on the simulation platform for void evolution, the optimum forging method can be designed, the most economical forging process can be arranged and the best forging quality can be achieved through the CAE analysis and optimization.
引文
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