1420六辊UCM冷连轧机板形控制性能分析与应用

以某1420六辊UCM冷连轧机为研究对象,利用Marc大型有限元软件平台建立了六辊UCM轧机辊系变形三维非线性仿真模型。通过数值模拟对各种板形调节量作用下的带钢弹塑性变形和轧辊弹性变形进行耦合分析,并深入研究了六辊UCM轧机工作辊弯辊、中间辊弯辊和中间辊横移等板形调控手段对带钢出口横向厚差、带钢金属横向位移和轧机辊系弯曲的调控效果,从而为辊型优化设计和板形在线控制提供了理论基础和参考依据。     

四辊轧机辊系压扁的有限元分析

应用非线性有限元软件MSC.Marc,采用三维弹塑性有限元法对四辊轧机轧制薄带钢的过程进行了模拟。计算模型将辊系与带钢作为整体统一考虑,解决了工作辊、支撑辊与带钢之间变形和受力的耦合问题,减少了计算过程中的假设,并采用逐步收敛的求解过程使计算结果精确、可靠。通过对模拟结果的分析,得出了轧制不同宽度带钢时工作辊、支撑辊的压扁分布,分析了带钢宽度对辊系压扁变形的影响。     

基于有限元的六辊轧机机架变形分析

针对以往机架设计中窗口尺寸与轴承座的配合间隙缺乏理论依据,且未考虑轧机辊系侧向力对机架窗口变形的影响,通过对某厂六辊轧机辊系的稳定性计算,求得轧辊辊系的水平力;采用有限元方法对轧机机架在轧制力和辊系水平力共同作用下的变形进行分析。结果表明,辊系轴承座侧向力对机架窗口水平方向的变形有很大影响,只有考虑了侧向力的作用,才能精确计算出机架窗口的变形。     

四辊平整机轧制过程辊系变形有限元分析

针对1800mm四辊平整机板形控制的弯辊力预设定问题,采用非线性弹塑性有限元法,建立四辊平整机轧制过程三维计算模型。模型将辊系弹性变形与轧件弹塑性变形耦合在一起,进行统一建模与分析,研究了不同轧制工艺下轧辊压扁、辊系弯曲变形及辊缝形状的分布规律,得出了工作辊弯辊力对辊系变形和辊缝变化的影响关系。计算结果可为建立平整机板形控制的弯辊力精确预设定模型提供理论依据。     

四辊轧机辊系刚柔耦合动力学建模研究

板带轧机的工作稳定性取决于系统的动力学特性,其中轧辊沿轴线方向的弯曲变形运动是影响板带厚度和表面质量的主要因素。几种运动形式相互影响、耦合作用,令轧机辊系成为一个复杂多变量动态系统。为综合考虑轧制过程中轧辊不同振动形式之间的耦合效应,同时考虑工作辊动特性与轧制外载荷动态增量之间的相互作用关系,本文分别建立了辊系刚柔耦合动力学模型、轧机系统刚性振动耦合动力学模型和轧制变形区耦合动力学模型。通过建立的四辊轧机刚柔耦合动力学模型体系,对轧制过程进行动态控制,仿真分析了轧制过程中轧机辊系和变形区内轧件的动力学特性。     

UCMW冷轧机轧辊变形特性研究

为优化轧辊辊形及提高辊系稳定性,以某设计院设计的1620 mm UCMW轧机为对象,结合具体生产数据,利用abaqus有限元软件建立了UCMW轧机二分之一辊系静力学仿真模型。通过仿真分析获得了轧制力、板宽、中间辊弯窜辊、工作辊弯窜辊、中间辊偏置等工艺参数对轧辊变形的影响规律。结果表明轧辊在压下方向变形影响最大的为中间辊的弯辊及窜辊,而中间辊偏置会对轧制方向变形产生影响,随着偏置量的增加,轧辊变形方向逐渐稳定。     

20辊森吉米尔轧机辊系稳定性研究

定义了森吉米尔轧机的辊系稳定性及稳定状态,对辊系的稳定条件进行了理论分析,推导出辊系稳定判据的解析表达式;借助MATLAB软件对某厂森吉米尔轧机的辊系稳定性进行了分析,得出了此轧机各轧辊的辊径使用范围。为了反映轧制过程中辊系变形对辊系稳定性以及稳定判据的影响,采用ADAMS动力学仿真软件对上述轧机进行了仿真分析,得出考虑辊系变形的各轧辊辊径使用范围与解析法的计算结果接近,说明辊系变形对辊系稳定性的影响较小,所建立的森吉米尔轧机辊系稳定判据可用于指导轧机辊系辊径配置。     

厚板轧机轧制区接触状态的有限元分析

应用大型非线性有限元软件MSC.Marc,建立了三维动态弹塑性全辊系有限元模型,对四辊轧机轧制厚带钢的过程进行模拟。与以往模型相比,该模型充分考虑了由于窜辊、辊形、单侧驱动等客观因素带来的辊系不对称特点,最大程度上减少了假设。基于模型,深入研究了不同带钢宽度时,轧制区轧件与工作辊间接触压力及摩擦力的三维分布情况,对研究厚板四辊轧机与带钢的接触状态及相关问题的解决,提供了理论依据。     

轧机刚度的有限元模拟

应用MSC．Marc有限元软件,采用线弹性分析和接触分析方法分别对某四辊冷轧机的机架和辊系进行了模拟,得出二者的变形,进而计算出轧机的整体刚度。将计算结果与实测轧机刚度比较,发现二者有很好的吻合,从而为模拟计算轧机刚度提供了依据。     

铝箔轧机辊系变形的有限元计算

用ANSYS有限元方法建立了铝箔轧机辊系变形数学模型 ,分别计算了不同轧件宽度时各轧制道次的辊缝及工作辊与支持辊间的压扁和压力的轴向分布 ,分析了不同轧件宽度时各道次铝箔的比例凸度及对板形的影响 ,与现场板形目测情况吻合。该计算方法可用做厚度大于 0 .1mm的铝箔轧机辊系变形数学模型。     

四辊板带轧机辊颈载荷分布及板形影响因素分析

板形是板带材产品的重要质量指标之一。辊系弹性变形是影响板形的主要因素,轧机辊颈载荷分布直接影响轧机的辊系弹性变形,因此精确分析辊颈载荷分布对板形控制和轴承使用有着重要的意义。针对实验室四辊可逆冷轧机,采用ANSYS/LS-DYNA有限元软件,基于显式动力学建立了耦合支撑辊轴承、轧辊和轧件的三维实体模型,分析了板宽、摩擦因数、张力和压下量等因素对支撑辊辊径载荷分布和板凸度的影响,对四辊板带轧机板形控制和轴承使用提供了理论支持。     

1200mm冷轧平整机设计与实践

分析了冷轧平整机辊型配置对带钢板形的影响因素和机理,对辊型进行计算与配置,将工作辊由平辊改为中凸形,支撑辊由平辊改为边部弧线形,提高弯辊和控制板形的效率,使带钢浪形缺陷的控制水平进一步提高。     

NUMERICAL SIMULATION FOR SHAPE OF COLD ROLLING ALUMINUM STRIP ON 4 HIGH MILL WITH ROLL SHIFTED

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Research on strip deformation in the cage roll-forming process of ERW round pipes

Cage roll forming is an advanced roll-forming technique to manufacture electric resistance welded (ERW) round pipes. In the cage roll-forming process, many small rolls are arranged along the outer surface of the deformable strip to bend the strip edge in a more smooth way. Furthermore, these small rolls can be used for forming pipes of different sizes. Therefore, cage roll forming can reduce roll change time and improve forming quality, as compared with the conventional step roll forming. However, very few studies can be found about cage roll forming, due to its complexity, and the industrial practice depends greatly on experience rather than science-based design today. In this work, the whole cage roll-forming process is simulated with the explicit elastic–plastic finite element method, and the strip deformation during the cage roll-forming process has been investigated in detail. Through the simulation, the “non-bending area” phenomenon is found, and the ranges of the non-bending area at different forming stands are obtained. In addition, the longitudinal strain at the inside edge and center are predicted, and by comparison, it can be known that the deformation of the strip edge is usually larger and edge buckling is most likely to occur at the entry sides of No.1–No.3 fin-pass stands. Finally, the circumferential length, opening distance and the profiles of the deformed strip are measured on the cage roll-forming mill. There is a good agreement between the experimental and simulated results.     

Coupling solved roll contact pressure transverse distribution of HC strip mill

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Analysis of rolls deflection of Sendzimir mill by 3D FEM

The deflection of rolls of Sendzimir mill with double AS-U-Roll was simulated by finite element method（FEM）. The influences of rolling pressure, strip width and rolls-assignment on rolls deflection were analyzed. The results show that the work roll deflection increases with the increase of rolling pressure and the reduction of work roll radius, but the rigid displacement of work roll slightly changes; the work roll end might appear negative displacement for the narrow strip width and high rolling pressure that might cause the contact of work rolls. The research results are significant for guiding production and theoretical analysis of the rolls system of Sendzimir mill.     

UCMW轧机带钢边缘降的成因分析与控制

带钢边部厚度减薄量是冷轧成品带钢一个重要质量指标。本文以宝钢１５５０ｍｍ ＵＣＭＷ 冷连轧机为研究对象,通过数值仿真,分析了冷轧带钢边部减薄的主要影响因素,研究了１５５０ｍｍ ＵＣＭＷ 冷连轧机配置的Ｋ-ＷＲＳ工作辊的边缘降控制性能,同时对其边缘降控制系统进行了消化分析,对比了边缘降控制系统投入前后的控制效果,以进一步指导实际生产。     

Rolling of T-shaped profiled strip by the satellite mill

A new type of compact mill called a “satellite mill” is used for producing T-shaped profiled strip from flat strip. The mill comprises one large-diameter flat roll (central roll) and five smaller-diameter caliber rolls (satellite rolls) arranged along the periphery of the central roll. The flat strip is continuously passed through the five gaps between the central roll and the satellite rolls and formed into a T shape. All rolls are driven at an equal peripheral speed to restrain elongation of strip and to promote transversal metal flow. A guide shoe is provided between each two adjacent satellite rolls to prevent the strip from bulging out or buckling. Using aluminum as a model material, some rolling experiments were performed on the mill. T-shaped profiled strips with a thickness ratio (thickness of thick part per thickness of thin part) as high as three were rolled successfully. When deformation and force characteristics were investigated, it was found that, in comparison to a conventional multipass caliber rolling, the elongation of the strip is suppressed and the filling ability is much improved.     

热轧精轧机组变接触支持辊综合性能研究

利用建立的有限元辊系弹性变形模型，分析了变接触支持辊（VCR）的综合性能。指出VCR可以显著改善轧机的板形调控性能。提高带钢的板形质量和支持辊辊形的自保持性，降低辊间接触压力尖峰，消除去持辊剥落。同时，在大型工业轧机上进行长时间的系统试验，验证了VCR的这些性质。     

CVC热连轧机支撑辊倒角的工作性能研究

分析了热连轧机支撑辊大圆弧复合型倒角的设计思想,并以某2250mm常规热连轧精轧机为例,运用基于影响函数法的辊系弹性变形理论,分析了不同支撑辊倒角参数对轧机板形控制性能的影响。结果表明,支撑辊倒角高度越大,承载辊缝横向刚度越大,但还需考虑带钢临界宽度对板形控制的影响;支撑辊倒角高度大的弯辊调控效果要优于倒角高度小的,且随着宽度的增加效果也会越明显;使用较小的支撑辊倒角高度可以在一定程度上改善轧辊磨损的不均匀性。