基于ProCAST数值模拟的高铬钢复合轧辊结合层夹渣成因分析
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摘要
为解决高铬钢复合轧辊离心复合铸造生产中的结合层夹渣问题,以复合铸造过程数值模拟与夹渣物XRD分析相结合,分析了该夹渣成分及分布原因。首先,通过宏观检查并利用XRD实验定性分析了夹渣物的组成,初步确定了夹渣物为生产中高温反应生成的非金属夹渣,且集中分布于辊身冒口端。其次,采用数值模拟的方法分析了高铬钢轧辊复合铸造的生产过程,对比研究了离心铸造和重力铸造2个阶段辊身冒口端与底端的高温金属流动与温度场演变差异。模拟结果表明:芯部重力铸造时,芯部高温金属液对轧辊外层冲刷作用的差异是夹渣物主要分布于辊身冒口端的重要原因。通过复合铸造过程流场与温度场的模拟结果,对高铬钢复合轧辊结合层夹渣物的产生和分布原因进行分析,对于改善离心铸造轧辊缺陷的产生具有借鉴意义。
In order to solve the slag inclusion on combining layer of high chrome steel composite roll produced by centrifugal compound casting, the reasons of the slag composition and distribution are investigated by means of compound casting process numerical simulation and slag inclusion XRD analysis. First of all, the composition of slag inclusion is qualitative analyzed based on the macro examination and XRD experiment, and slag inclusion is preliminarily identified as non-metallic slag generated by the high temperature reaction in the production process, which is distributed in the roll the riser end. Then, the production process of compound casting is analyzed by using the method of numerical simulation. Metal flow field and temperature field of bottom and the riser end on roll body during the centrifugal stage and gravity stage are compared. The simulation results show that the scouring action different of hot metal liquid on the outer layer of rolls is the important reason in slag inclusion distribution. Based on the simulation results of flow field and temperature field in the process of compound casting, the generation and distribution reasons of slag inclusion in the bonding layer of high chromium steel composite roll is analyzed, which has certain reference for reducing defects during the generation of centrifugal casting roll.
In order to solve the slag inclusion on combining layer of high chrome steel composite roll produced by centrifugal compound casting, the reasons of the slag composition and distribution are investigated by means of compound casting process numerical simulation and slag inclusion XRD analysis. First of all, the composition of slag inclusion is qualitative analyzed based on the macro examination and XRD experiment, and slag inclusion is preliminarily identified as non-metallic slag generated by the high temperature reaction in the production process, which is distributed in the roll the riser end. Then, the production process of compound casting is analyzed by using the method of numerical simulation. Metal flow field and temperature field of bottom and the riser end on roll body during the centrifugal stage and gravity stage are compared. The simulation results show that the scouring action different of hot metal liquid on the outer layer of rolls is the important reason in slag inclusion distribution. Based on the simulation results of flow field and temperature field in the process of compound casting, the generation and distribution reasons of slag inclusion in the bonding layer of high chromium steel composite roll is analyzed, which has certain reference for reducing defects during the generation of centrifugal casting roll.
引文
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[13] 李济玉.铸造轧辊疑难技术的解决方法[J].铸造工程,2016,40(2):24-26.LI Jiyu.Solutions of cast roll difficult technology[J].Foundry Engineering,2016,40(2):24-26.
[14] 李三华,陈建文,周崇文,等.衡山钠长石湿法选矿提纯试验研究[J].中国非金属矿工业导刊,2018(4):10-12.LI Sanhua,CHEN Jianwen,ZHOU Chongwen,et al.Study on purification of sodium feldspar wet dressing in Hengshan mountain[J].China Non-Metallic Minerals Industry,2018(4):10-12.
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[16] 陈刚,李和平,苗社强.高温高压下钠长石集合体热扩散系数的实验研究[J].矿物学报,2016,36(1):7-11.CHEN Gang,LI Heping,MIAO Sheqiang.Experimental study on thermal diffusivity for albite aggregates under the condition of high temperature and high pressure[J].Acta Mineralogica Sinica,2016,36(1):7-11.
[17] 于晓杰.复合轧辊离心浇注用玻璃渣粘度大原因分析[C]//2015全国轧辊使用与制造技术交流会论文集.唐山:河北省冶金学会,山东金属学会,江苏省金属学会,2015:39-40.
[18] 郭国林,徐向珍,李金阳.西藏普兰地幔橄榄岩中尖晶石内的钙长石包裹体及其成因[J].岩石学报,2011,27(11):3197-3206.GUO Guolin,XU Xiangzhen,LI Jinyang.The character and genesis of anorthite as inclusions in spinel of mantle peridotites from the Purang ophiolite (southwestern Tibetan Plateau)[J].Acta Petrologica Sinica,2011,27(11):3197-3206.
[2] 赵亮,贾宝瑞,郑兴跃.高铬钢粗轧辊带裂纹在CSP轧机上使用探索[J].金属世界,2017(1):64-66.ZHAO Liang,JIA Baorui,ZHENG Xingyue.Application exploration of crack high-Cr steel roughing roll on CSP rolling line[J].Metal World,2017(1):64-66.
[3] LU Suling,XIAO Furen,ZHANG Shuangjie,et al.Simulation study on the centrifugal casting wet-type cylinder liner based on ProCAST [J].Applied Thermal Engineering,2014,73(1):512-521.
[4] DROBNE M,G?NCZB P,GLODE?B S.Fatigue behavior of high chromium steel for rolls[J].Procedia Engineering,2011,10:1202-1207.
[5] 张德明.高铬钢工作轧辊辊身夹渣研究[N].世界金属导报,2017-08-29(B06).
[6] 刘宝存,左素敏.离心复合高铬钢轧辊差温热处理工艺[J].中国铸造装备与技术,2015(4):18-20.LIU Baocun,ZUO Sumin.Poor warm treatment of centrifugal compound high-chromium steel roll[J].China Foundry Machinery & Technology,2015(4):18-20.
[7] 杨智强,起华荣,郭红星,等.高碳高速钢离心复合轧辊铸造缺陷形成及预防工艺研究[J].铸造技术,2018,39(4):848-850.YANG Zhiqiang,QI Huarong,GUO Hongxing,et al.Study on formation and prevention of centrifugal casting defects in high carbon high speed steel compound roller[J].Foundry Technology,2018,39(4):848-850.
[8] TAN E,TARAKCILAR A R,DISPINAR D.Defect analysis by casting simulation software in rolling roll manufactured by GGG70[C]// CFD Modeling and Simulation in Materials Processing.[S.l.]:[s.n.],2012:213-218.
[9] 肖连华,曹瑞荣.离心铸造铸铁轧辊夹渣产生原因及改进措施[J].现代铸铁,2018,38(6):37-40.XIAO Lianhua,CAO Ruirong.Causes and improvement measures of slag inclusion in centrifugal casting iron rolls[J].Modern Cast Iron,2018,38(6):37-40.
[10] AZEVEDO C R F,MAIA R R,ARIZA E A,et al.Failure analysis of a martensitic stainless steel (CA-15M) roll manufactured by centrifugal casting.Part I:Material and fractographic characterization[J].Engineering Failure Analysis,2014,36(1):343-352.
[11] ARIZA E A,TSCHIPTSCHIN A P,AZEVEDO C R F.Failure analysis of a martensitic stainless steel (CA-15M) roll manufactured by centrifugal casting.Part II:Thermal stress analysis by FEA[J].Engineering Failure Analysis,2015,48(2):78-93.
[12] 王素平,高志江,张翠英.离心复合铸铁轧辊铸造缺陷的分析及对策[J].河北冶金,2012(1):34-36.WANG Suping,GAO Zhijiang,ZHANG Cuiying.Analysis and conunter measures for casting defect in centrifugal complex cast iron roll[J].Hebei Metallurgy,2012(1):34-36.
[13] 李济玉.铸造轧辊疑难技术的解决方法[J].铸造工程,2016,40(2):24-26.LI Jiyu.Solutions of cast roll difficult technology[J].Foundry Engineering,2016,40(2):24-26.
[14] 李三华,陈建文,周崇文,等.衡山钠长石湿法选矿提纯试验研究[J].中国非金属矿工业导刊,2018(4):10-12.LI Sanhua,CHEN Jianwen,ZHOU Chongwen,et al.Study on purification of sodium feldspar wet dressing in Hengshan mountain[J].China Non-Metallic Minerals Industry,2018(4):10-12.
[15] 李帆,邱建荣,郑瑛,等.煤燃烧过程矿物质行为研究[J].工程热物理学报,1999,20(2):258-260.LI Fan,QIU Jianrong,ZHENG Ying,et al.Study on behavior of mineral matters in coal during burning process[J].Journal of Engineering Thermophysics,1999,20(2):258-260.
[16] 陈刚,李和平,苗社强.高温高压下钠长石集合体热扩散系数的实验研究[J].矿物学报,2016,36(1):7-11.CHEN Gang,LI Heping,MIAO Sheqiang.Experimental study on thermal diffusivity for albite aggregates under the condition of high temperature and high pressure[J].Acta Mineralogica Sinica,2016,36(1):7-11.
[17] 于晓杰.复合轧辊离心浇注用玻璃渣粘度大原因分析[C]//2015全国轧辊使用与制造技术交流会论文集.唐山:河北省冶金学会,山东金属学会,江苏省金属学会,2015:39-40.
[18] 郭国林,徐向珍,李金阳.西藏普兰地幔橄榄岩中尖晶石内的钙长石包裹体及其成因[J].岩石学报,2011,27(11):3197-3206.GUO Guolin,XU Xiangzhen,LI Jinyang.The character and genesis of anorthite as inclusions in spinel of mantle peridotites from the Purang ophiolite (southwestern Tibetan Plateau)[J].Acta Petrologica Sinica,2011,27(11):3197-3206.