An automated Thixo‐Forging Plant for Steel Parts

The scope of the article is to describe the automated production of a thixoformed steel part. The production plant was set up within a prototype initiative at the Institute of Metal Forming in cooperation with the Institute of Automatic Control of RWTH Aachen University and industrial partners. Preliminary experiments showed that the quality of the formed parts varied to a great extent due to changing production conditions since the handling of the billet was carried out manually. To eliminate the possible disturbances introduced by the manual handling of the billet, an automation concept has been elaborated in order to guarantee a defined production environment. An industrial robot (KUKA) fulfils the handling tasks like the feeding of the induction coil with the feedstock material and the placing of the heated billet into the hydraulic press. The removal of the formed part from the press is realised by a simple mechanical device in order to be able to use only one gripper. The design of the gripper ensures a minimal heat loss during handling. The induction coil, the gripper system and the cavity are flooded with inert gas in order to prevent scaling. The sequence control for the production of a part is realised on the controller of the robot which provides sufficient PLC functionality and can be easily equipped with the required I/O components to trigger the different automation components.     

冷轧机工作辊非对称弯辊的板形调控理论研究与应用

为减少冷轧带钢的非对称板形缺陷的产生,设计了工作辊非对称弯辊控制系统.应用影响函数法计算辊系变形,同时考虑辊缝中金属横向流动对带钢出口横向张力分布的影响,通过迭代法计算出工作辊两端施加不同弯辊力后的辊间压力分布、出口厚度横向分布以及出口横向张应力分布.理论分析结果表明,工作辊非对称弯辊可以在一定程度上改善辊间压力分布不均,减轻轧辊磨损和减少轧辊掉皮事故的发生,降低带钢边部的非对称板形缺陷.实际应用结果证明,当倾斜调整量小于10%时,应用工作辊非对称弯辊替代倾斜调整,可以获得更好的板形精度.      

Coherent Structures in the Flow Field around a Circular Cylinder with Scour Hole

Large-eddy simulation (LES) and laboratory-flume visualizations were used to investigate coherent structures present in the flow field around a circular cylinder located in a scour hole. The bathymetry corresponds to equilibrium scour conditions and is fixed in LES. The flow parameters in the simulation correspond to the experimental conditions in which the approach flow is fully turbulent. Detailed consideration is given to the interaction of the horseshoe vortex (HV) system within the scour hole with the detached shear layers formed from the cylinder, and the near bed turbulence. It is found that the overall structure of the HV system varies considerably in space and time, though a large, relatively stable, primary necklace vortex is present at practically all times inside the scour hole. The simulation captures the presence of bimodal chaotic oscillations inside the HV system, as well as the sharp increase in the resolved turbulent kinetic energy levels and pressure fluctuations reported in prior experimental investigations. High levels of the mean bed shear stress are observed beneath the primary necklace vortex, especially over the region where the bimodal oscillations are strong, as well as beneath the small junction vortex at the base of the cylinder. It is also found that the detachment and advection of patches of vorticity from the downstream part of the legs of the necklace vortices can induce large instantaneous bed shear stress values. When the critical bed shear stress value for sediment entrainment on a flat surface is adjusted for bed slope effects, the LES simulation correctly predicts that the distribution of the mean bed shear stress is consistent with equilibrium scour conditions.     

超音速雾化器的气体流场分布研究

利用Pitot管对超音速雾化器出口处的气体流场分布进行了研究。研究结果表明，在出口处的雾化气体呈轴线近似对称的双峰分布，峰值沿着远离导液管出口端面的方向而逐渐减小。通过对气体流场分布的分析，提出倒涡流锥概念，可以很好的解释导液管下端形成负压的原因，并认为理想的雾化过程是在倒涡流锥范围内完成的。     

Enrichment of Methane Concentration via Separation of Gases using Vortex Tubes

The objective of this work was to determine if a vortex tube can be used as a gas separation device. A vortex tube is a simple mechanical device that has no moving parts. It separates a compressed inlet fluid into two streams, one hot and the other cold. There are a variety of theories to explain this separation. It has been hypothesized that a mixture of compressed gases flown into the vortex tube may separate into individual gas streams by virtue of differential centrifugal forces acting on them. During previous studies by others, conflicting results have been obtained using this hypothesis. Further study of the gas separation process in a vortex tube was carried out. An attempt has been made to separate methane and nitrogen gases using vortex tubes. This particular separation or the resulting enrichment of Methane concentration has applications in the mining industry. Methane is emitted in an underground coal mine. It leaks from the coal seams and is extremely hazardous for workers because of its high explosivity in air. A conventional but costly means of circumventing this problem is methane drainage before mining. Yet another effective method is to blow large amount of air through the mine to locally dilute methane concentration. The mixture of methane and air is directly passed into the atmosphere. There are advantages to separating methane from air at the ventilation exhaust of the mine. First, methane being a greenhouse gas has strict EPA emission standards, and second, methane can be directly used for generating power. In this experimental work, a laboratory size setup was used to investigate the feasibility of using a fixed geometry vortex tube for separating methane and nitrogen from a mixture. It was found that there was partial gas separation leading to a higher concentration of methane at one exit in comparison to the inlet and a lower concentration at the other exit.     

Hydraulics of Tangential Vortex Intake for Urban Drainage

A tangential vortex intake is a compact structure that can convey storm water efficiently as a swirling flow down a vortex dropshaft. It has been studied in physical models and successfully employed in urban drainage and hydroelectric plant applications, but a comprehensive account of the key flow characteristics has not been reported and a theoretical design guideline of a tangential intake is not available. In this study the hydraulics of tangential slot vortex intakes is investigated via extensive experiments. It is found that the flow in the tapering and downward sloping vortex inlet channel is strongly dependent on the geometry of the inlet and dropshaft. Under some conditions, hydraulic instability and overflow can occur, rendering the design ineffective. It is shown that the hydraulic stability depends on the discharge at which flow control shifts from upstream to downstream (Qc), as well as the free drainage discharge (Qf). A theoretical design criterion for stable flow is developed in terms of Qf and Qc as a function of the vortex inlet geometry. For a “stable” design, the flow in the tapering inlet evolves from supercritical flow to subcritical flow smoothly as the discharge increases. Fifteen different tangential vortex intake models are tested. The experimental observations are in excellent agreement with the theoretical prediction. The present study provides a general guideline for designing a tangential vortex intake that can convey the flow smoothly without unstable fluctuating flow associated with a hydraulic jump.     

Simulation of the submerged energy nozzle-mold water model system using laser-optical and computational fluid dynamics methods

The present work describes quantitative digital particle image velocimetry measurements of a full-scale water model of a thin slab mold. Different casting speeds and two submerged entry nozzles with one and two outlet ports have been investigated. The flow pattern of the single-port nozzle shows a counterclockwise-rotating double vortex that is nearly steady-state but leads to high stationary surface waves. The flow jets out of the two-port nozzle oscillate and produce a transient flow pattern with low wave amplitudes. The amplitudes for the one-port nozzle show a linear variation with the volumetric flow rate. The experimental results lead to a good interpretation of the flow phenomena and are used to validate steady-state numerical simulations with the commercial program, CFX, on the basis of the Reynolds equations. To describe anisotropic turbulence effects, the Reynolds stress model (RSM) is used for the flat single-port nozzle and the standard k-ɛ model for the mold flow. The calculated mean velocities and wave amplitudes, predicted from pressure distribution at the water surface, are generally in the consensus of the experimental data. An erratum to this article is available at .     

热轧带钢传热模拟及变形区换热系数的确定

采用数值模拟方法研究了带钢热轧区轧件传热和温度场分布规律.结合现场生产中测温数据,建立了轧制变形区内轧件与轧辊接触传热界面换热系数(HTC)统计模型.分析了辊缝变形区中轧件断面上温度演变和分布特点.研究结果表明,热轧带钢热轧区传热数值模拟计算结果与实际吻合良好;变形区内轧件与轧辊接触传热界面换热系数不仅与平均单位压力相关,而且与轧制速度相关;轧件在轧制变形区存在很大的温度梯度.     

Effect of Seepage-Induced Nonhydrostatic Pressure Distribution on Bed-Load Transport and Bed Morphodynamics

Bed-load transport is commonly evaluated in the condition of a hydrostatic pressure distribution of the flow field; while this condition is reasonable for quasi-steady, quasi-uniform rectilinear flows, it cannot be satisfied in a large variety of flow conditions, i.e., near an obstacle as in the case of a bridge pier. The dimensionless Shields number, which contains the assumption of a hydrostatic pressure distribution in its denominator, therefore cannot be strictly applied to evaluate bed-load transport in all the configurations where nonhydrostatic pressure distributions are observed. In the present work, a generalization of the Shields number is proposed for the case of nonhydrostatic pressure distribution produced by groundwater flow. Experiments showing the effects of vertical groundwater flow on the bed morphodynamics are presented. The comparison between the experimental observations and numerical results, obtained by means of a morphodynamic model which employs the new formulation of the Shields number, suggests that the proposed generalization of the Shields number is able to account the effect of the nonhydrostatic pressure distribution on the bed-load transport.     

1400mm十二辊轧机轧辊间的接触压力三维光弹分析

为了准确描述1 400 mm十二辊轧机轧辊间的接触压力分布规律,以有效改善其轧件的横向厚度差和板形,应用应力相似准则设计了1 400 mm十二辊轧机光弹模型,并用三维光弹性应力分析原理,实验确定1 400 mm十二辊轧机光弹模型的辊间接触压力的分布规律,并依据应力相似转换准则,计算出其实际轧机辊间接触压力分布.     

Characteristics of Steady Horseshoe Vortex System near Junction of Square Cylinder and Base Plate

This paper presents an experimental investigation on the characteristics of a horseshoe vortex system near the juncture of a square cylinder and a horizontal base plate, using particle image velocimetry and flow visualization technique. Experiments were conducted for Reynolds numbers (based on the free stream velocity and the width of square cylinder) ranging from 2.0×102 to 6.0×103. The flow patterns are first classified into four major regimes: Steady horseshoe vortex system, periodic oscillation vortex system with small displacement, periodic breakaway vortex system, and irregular vortex system. The classifications can be demonstrated as a figure of Reynolds number versus the ratio of the height of square cylinder to undisturbed boundary layer thickness. The study then mainly focused on the characteristics of steady horseshoe vortex system (corresponding to Reynolds numbers ranging from 2.0×102 to 2.5×103). The nondimensional characteristics, including the horizontal and vertical distances from the primary vortex core to frontal face of the vertical square cylinder and bottom boundary of the base plate, respectively, the height of stagnation point at frontal face of the square cylinder, and the down-flow discharge as well as circulation of the primary vortex, all increase with increase of the ratio of the height of square cylinder to undisturbed boundary layer thickness. However, they all decrease with the increase of the aspect ratio (i.e., the height-to-width ratio) of the square cylinder. The study provides essential properties of a steady horseshoe vortex system and gives an insight for related engineering applications. It can be served as a basis for more complicated horseshoe vortex systems occurring at high Reynolds numbers.     

多流式连铸过渡包的结构优化

摘要：过渡包在薄带连铸过程中起到承上启下的作用,为了使结晶器入口钢液成分与温度更加均一,研究钢液在过渡包内的流动以及其出口钢液温度的分布对薄带连铸过程有着重要的意义。针对某钢厂多流式过渡包,提出在包内增加坝堰组合以优化钢液在包内的流态以及温度分布。采用数值模拟和物理模拟的方法,研究了过渡包内不同控流装置下钢液的流态和温度分布,同时通过各流出口的平均停留时间和温度值差来考察钢液分布的均匀性。研究发现增加坝堰组合后,过渡包内流态与温度分布更加均一且稳定,过渡包内设置坝高30mm,堰高30mm,坝堰间距120mm,堰距入口中心距离253mm为最优方案,其平均停留时间方差较原模型减少82%,各出口温度极差较原模型减少67%。数值模拟结果同物理模拟结果较一致。     

热轧U型钢板桩精轧过程金属流动行为的有限元分析

针对热轧U型钢板桩(SY390BZ/%:0.23C、1.60Mn、0.44Si、0.18V,0.18Ti、0.05Nb)轧制过程中产生翘曲缺陷,采用有限元分析软件ABAQUS显式动力学算法,结合实验室试验测量参数,对钢板桩的精轧过程进行了仿真计算。在仿真计算的基础上,根据轧制平面内节点位移矢量分布情况,分析了轧件横向和纵向断面内金属流动规律。模拟结果显示轧件断面在孔型轧制的压下方向上存在零位移线,表明U型钢板桩轧制中坯料翼缘和锁口处在轧制压力方向上轧件内金属流动存在位移中性面,并伴有轧件锁口凸缘处金属流动过快,腹板处金属流动较慢而产生翘曲的现象。     

Two-phase sink vortex suction mechanism and penetration dynamic characteristics in ladle teeming process

At the late stage of continuous casting (CC) ladle teeming,sink vortex can suck the liquid slag into tundish,and cause negative influences on the cleanliness of molten steel.To address this issue,a two-phase fluid mechanical modeling method for ladle teeming was proposed.Firstly,a dynamic model for vortex suction process was built,and the profiles of vortex flow field were acquired.Then,based on the level set method (LSM),a two-phase 3D interface coupling model for slag entrapment was built.Finally,in combination with high-order essentially non-oscillatory (ENO) and total variation diminishing (TVD) methods,a LSM-based numerical solution method was proposed to obtain the 3D coupling evolution regularities in vortex suction process.Numerical results show that the vortex with higher kinetic energy can form an expanded sandglass-shape region with larger slag fraction and lower rotating velocity;there is a pressure oscillation phenomenon at the vortex penetration state,which is caused by the energy shock of two-phase vortex penetration coupling.     

Turbulent flow field over fluvial obstacle marks generated in a laboratory flume

The study is aimed at investigating the mean flow and turbulence characteristics in scour geometry developed near a circular cylinder of length 10cm placed over the sand bed transverse to the flow. The obstacle placed on a sand bed, on the way of a unidirectional flow, develops a crescent-shaped scour mark on the bed. The scour is caused by generation of vortex developed on the upstream side of the obstacle. Sand grains eroded by this vortex, are deposited on the downstream side of the obstacle as wakes. The turbulent flow field within the scour mark was measured in a laboratory flume using an Acoustic Doppler Velocimeter (ADV). The scour marks named as current crescents preserved in geological record are traditionally used as indicators of palaeocurrent direction. The distribution of mean velocity components, turbulent intensities and Reynolds stresses at different positions of the mark are presented. The experimental evidence also shows that the geometric characteristics of the scour mark (width) depend primarily on the cylinder aspect ratio, cylinder Reynolds number and sediment Froude number.     

Three-Dimensional Model for Strip Hot Rolling

Steel stripis widely usedin many fields such asautomobile ,building,transportation and householdappliance ,etc·. Withthei mprovement in productiv-ity and automation of strip processing,the require-ments for crown and flatness of strip have been in-creasingly severe ,and“crown free”steel strips arerequired for some special applications such as for au-tomobile parts andtinplate cans .In order toi mprovethe strip quality , an effective three-di mensionalmodel is needful to further study on the…     

Vortex Plate for Enhancing Particle Settling

The feasibility of enhancing suspended solids settling by using the newly proposed vortex plates in clarifiers, instead of conventional smooth lamellae, was studied using computational fluid dynamics (CFD) modeling and laboratory experiments in which suspended particles were mimicked by crushed walnut shells and glass beads. The vortex plate was formed by attaching perpendicular ribs to the plate, forming slots of 25×25?mm (depth×width) and placing the plate parallel to the longitudinal clarifier axis at an angle of 60° from the horizontal. Rib walls were placed either in vertical planes, perpendicular to the clarifier longitudinal axis, or were slightly sloping in the main flow direction (20° about the vertical). Three hydraulic concepts were explored with respect to enhancing suspended particle settling: (1) the use of flow energy to generate steady vortices inside the slots and thereby entrain particles into the slots, where they would be sheltered from the fast horizontal flow and could settle without much hindrance; (2) enhancing the particle settling by increasing the contact surface area and thereby reducing the length of travel of settling particles; the same principle is used in conventional lamellar settlers but the surface area of a vortex plate is three times that of a smooth lamella; and (3) increasing the particle collision frequency within the swirling flow inside slots to prompt particle flocculation. The CFD modeling and experimental observations confirmed the formation of strong vortices in the parallel slots of the vortex plate. Such vortices entrained the passing by particles and retained some of them in slots, which provided a quiescent settling zone. Both the simulation and measured results indicated that the vortex plate contributed to a slightly improved removal of suspended particles. A CFD particle tracking model was applied to clarifiers with two vortex plates or two smooth plates and indicated that the vortex plate removed about 8% more particles than the smooth plate. In laboratory tests with plate arrays, the vortex plate array also contributed to better particle removals, especially for slower settling particles and larger inflow rates (by up to 26%).     

CH3SiCl3-H2-Ar 化学气相沉积SiC 简化反应模拟

为了生产大面积、均匀的SiC涂层,需要对反应室内不同位置的沉积速率变化规律进行研究。将CH₃SiCl₃-H₂-Ar体系化学气相沉积SiC过程简化为气相裂解、表面沉积两步,建立反应室二维反应?输运模型;利用计算流体力学(computational fluid dynamics,CFD)软件分析气流量、温度和压力对炉内垂直高度方向上沉积速率的影响。结果表明:不同气流量下,因气流滞留时间不同,沉积分布呈现不同的趋势,适中流量时沉积厚度均匀性较好,沉积速率较高;提高温度能改善高流速下沉积的不均匀性;流量一定,压力过高会引起自然对流漩涡。对比计算结果与相关实验数据,该两步简化模型可以反映不同条件下反应物的消耗和涂层的均匀性。     

辊形配置对辊间接触压力与板形调控影响分析

为系统分析不同辊形配置下辊间接触压力分布形式与板形调控特性,以某1 800 mm热轧生产线使用的2种典型辊形配置为研究对象,建立对应的辊系有限元模型,计算不同带钢规格与调控手段下辊间接触压力分布形式,分析得出常规凸度支撑辊对应的辊间接触压力分布形式与CVC工作辊辊形呈现出明显的对应性,且压力分布形式受轧制规格与调控手段的影响明显小于CVC支撑辊。利用接触压力峰值和不均匀度表述辊间接触压力分布特征,将不同规格与调控手段对辊间接触压力分布特征的影响进行量化处理,得到更为具体的不同参量在整个变化范围内对分布特征的整体影响趋势。同时还对2种辊形配置下不同辊间接触压力对轧机板形调控特性影响进行分析,得出CVC支撑辊对应辊形配置的弯辊力与窜辊位置在板形调控能力上均强于常规凸度支撑辊辊形配置,而不同辊形配置对辊缝形状的影响表现出较为明显的差异,引入辊间接触压力边中比得到调控特性与辊间接触压力之间的具体关系,并结合现场的实际生产数据对仿真分析结果进行验证,研究结果可为现场辊形配置与板形调控提供较好的理论基础和生产指导。