CN110941889A - Research method for micro and macro crack germination and propagation of continuous casting special-shaped blank - Google Patents
Research method for micro and macro crack germination and propagation of continuous casting special-shaped blank Download PDFInfo
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Abstract
The invention discloses a research method for the germination and expansion of micro and macro cracks of a continuous casting special-shaped blank, which simulates a temperature field and a stress field of the special-shaped blank in a crystallizer through ANSYS so as to find out the position where a casting blank crack is most easy to be initiated and expanded; then simulating the expansion behavior of the surface crack of the casting blank based on XFEM by adopting ABAQUS finite element software and an expansion finite element method and combining a high-temperature fracture experiment; and finally, the stress and the displacement of the crack tip unit are obtained through calculation in the last step, and the initiation and the expansion behaviors of the crystal crack under the microscopic condition are simulated by taking the stress and the displacement as boundary conditions. Optimization suggestions on production process conditions can be provided so as to reduce defects on the surface of the casting blank, particularly the problem of cracks, and the problem that the surface cracks of the special-shaped blank are difficult to effectively solve in the current engineering is solved.
Description
Technical Field
The present invention relates to continuous metal casting, and is especially the research method of micro and macro crack germination and propagation in continuous casting of special blank.
Background
In the continuous casting process, various defects are inevitably generated, and the proportion of casting blank cracks in the various defects is as high as about 50 percent. This problem is exacerbated by the complex shape of the cross-section of the blank. The generation of cracks in the casting blank seriously affects the production efficiency and the product quality. In order to improve the situation, a great deal of work is done by many scholars on the formation reason and the control method of the surface cracks of the continuous casting billet, wherein the study on the influence of factors such as molten steel components, drawing speed, covering slag thickness, crystallizer vibration and the like on the surface cracks of the continuous casting billet is included, and the measures such as adopting a gradual straightening technology and protecting casting in the whole process are proposed for continuous casting process operation equipment to reduce the generation of the cracks.
However, the above studies have mainly focused on macroscopic qualitative analysis of production data and theoretical analysis, and have been conducted on the basis of conventional billets. The research on the crack initiation and expansion process in the production process of the beam blank is less, and the research on the thermal coupling model for analyzing the crack initiation and expansion is almost not established based on the stress genetic characteristic of the continuous casting blank shell, and particularly the research on the crack expansion simulation of the crystal model is very little.
Disclosure of Invention
The invention aims to solve the technical problem of providing a method for researching the germination and the propagation of the micro and the macro cracks of the continuous casting special-shaped blank, which integrates the whole process of the research on the germination and the propagation of the micro and the macro cracks of the continuous casting blank, analyzes the interaction rule of the macro and the micro surface cracks of the casting blank through highly scientific analysis and planning calculation of the whole system, and discusses a macro process parameter optimization scheme on the basis, thereby providing an optimization suggestion on production process conditions to reduce the defects of the surface of the casting blank, particularly the problem of cracks, and solving the problem that the surface cracks of the special-shaped blank are difficult to effectively solve in the current engineering.
In order to solve the technical problems, the invention adopts the following technical means:
the method for researching the germination and propagation of the micro-cracks and the macrocracks of the continuous casting billets comprises the following steps:
1) thermal coupling analysis in the special-shaped blank continuous casting crystallizer is based on the stress genetic characteristic of a continuous casting blank shell, the fact that a stress field can be continuously inherited in continuous casting is considered, so that defects at the upper part can be reflected at the lower part, a casting blank solidification thermal coupling model in the crystallizer is established by using a multi-load step method, under the condition that the taper and the air gap are considered, a temperature field and a stress field simulated according to ANSYS are calculated, the blank shell thickness, the equivalent stress, the maximum main stress and the width surface stress at each position of the temperature field and the casting blank are calculated, and the position where a casting blank crack is most prone to be initiated and expanded is found out;
2) performing macroscopic crack propagation research on the beam blank surface, testing the yield stress and the fracture toughness of the material at high temperature by using GLEEBLE-3500, and performing initial crack propagation dynamic simulation by using a large finite element analysis software ABAQUS and an X-FEM method combined with the ABAQUS on the basis of the theory of fracture mechanics to simulate the propagation condition of the surface crack at the beam blank web and the R angle in the crystallizer;
3) the method comprises the steps of simulating crack initiation and propagation in a special-shaped blank crystal, establishing a special-shaped blank polycrystalline model through MATLAB, and performing stress strain analysis of a defect-free crystal, polycrystalline model analysis containing a plurality of cracks, polycrystalline model analysis containing different porosities and polycrystalline model analysis containing inclusions in different proportions in ABAQUS software by utilizing a complete implicit stress iterative algorithm based on microscopic damage mechanics to simulate the crack propagation of the polycrystalline model.
Compared with the prior art, the invention adopting the technical scheme has the outstanding characteristics that:
step 1) finding out the position where the casting blank cracks are most prone to be initiated and expanded, and step 2) simulating the expansion condition of the surface cracks at the web and the R angle of the beam blank in the crystallizer, so as to provide a foundation for deep research on the surface crack expansion of the beam blank; and 3) carrying out crack propagation simulation on the polycrystalline model, and providing theoretical guidance for generation of macrocracks and process optimization.
According to the technical scheme, the temperature field and the stress field of the special-shaped blank in the crystallizer are simulated through ANSYS, so that the position where the casting blank crack is most prone to being initiated and expanded is found out; then simulating the expansion behavior of the surface crack of the casting blank based on XFEM by adopting ABAQUS finite element software and an expansion finite element method and combining a high-temperature fracture experiment; and finally, the stress and the displacement of the crack tip unit obtained through the calculation in the previous step are used as boundary conditions to simulate the crystal crack initiation and propagation behaviors under the microscopic condition, so that a theoretical basis is provided for reducing the surface cracks of the casting blank.
Compared with the prior art, the invention adopting the technical research scheme adopts the research methods of thermal coupling analysis in the beam blank continuous casting crystallizer, beam blank surface crack macroscopic expansion research, crack initiation and expansion in the beam blank crystal simulating multi-objective optimization of the microscopic and macroscopic crack germination and expansion of the continuous casting blank, thereby proposing the optimization suggestion of the production process conditions, reducing the surface defects of the casting blank, particularly the surface crack problem, and solving the problem that the surface crack of the beam blank is difficult to effectively analyze and control in the current engineering. The invention integrates the whole process of the research on the germination and the propagation of the micro and macro cracks of the continuous casting billet, analyzes the rule of the interaction between the macro and micro surface cracks of the casting billet by the highly scientific analysis and planning of the whole system, and discusses the optimization scheme of the macro process parameters on the basis.
Drawings
FIG. 1 is a block diagram of the thermal coupling procedure based on the genetic property of stress according to the present invention.
FIG. 2 is a block diagram of the macro crack propagation step of the present invention.
FIG. 3 is a block diagram of simulation steps for crack initiation and propagation in a shaped blank crystal according to the present invention.
Fig. 4 is a cloud of temperature profiles for different positions of the preforms in the mold.
Fig. 5 is a temperature change curve of each characteristic point.
FIG. 6 is a graph showing the variation of the shell thickness of the blank in the mold at each location of the blank.
FIG. 7 is a cloud of equivalent stress distributions of the cast slab at 175mm, 350mm, 525mm and 700mm from the meniscus of the mold.
Fig. 8 is a diagram of the maximum principal stress cloud of a cast strand at different positions in the mould.
Fig. 9 is a maximum principal stress variation curve at each characteristic point.
FIG. 10 is a stress variation curve of a wide surface of a casting slab at different positions of a mold at each characteristic point of the casting slab.
FIG. 11 is a stress variation curve of a narrow face at different positions of a mold at each characteristic point of a cast slab.
FIG. 12 is a sub-model and pre-crack map.
FIG. 13 is a view of surface longitudinal crack propagation at the web.
FIG. 14 is a graph of crack propagation at 30 to the direction of pull at the web.
FIG. 15 is a longitudinal crack view at angle R.
FIG. 16 is a crack propagation plot at 30 to the direction of pull at angle R.
FIG. 17 is a schematic diagram of the establishment of a polycrystalline model.
FIG. 18 is a graph of the load distribution of the polycrystalline model in ABAQUS.
FIG. 19 is a defect-free polycrystalline model stress distribution plot.
FIG. 20 is a crack propagation plot at 15 from the load direction.
FIG. 21 is a crack propagation plot at 90 to the load direction.
FIG. 22 is a stress distribution plot for polycrystalline models of different porosities.
FIG. 23 is a stress distribution plot for polycrystalline models of different inclusion ratios.
FIG. 24 is a diagram of a 45 crack primary polycrystalline model.
FIG. 25 is a PHILSM cloud of a 45 ° crack polycrystalline model at a pull rate of 0.9 m/min.
FIG. 26 is a cloud of PHILSM of a 45 ° crack polycrystalline model at a pull rate of 1.2 m/min.
FIG. 27 is a PHILSM cloud of a 45 ° crack polycrystalline model at 15 ℃ superheat.
FIG. 28 is a PHILSM cloud of a 45 ° crack polycrystalline model at 45 ℃ superheat.
Detailed Description
The present invention will be further described with reference to the following examples.
The present invention is further illustrated by the following examples, which are not intended to limit the scope of the present invention in any way.
Example 1
The research method for the germination and propagation of the micro-cracks and the macro-cracks of the continuous casting special-shaped blanks comprises the following steps:
step 1) with reference to fig. 1, it can be known that the thermal coupling analysis in the beam blank continuous casting crystallizer is based on the continuous casting blank shell stress genetic characteristic, that is, the fact that the stress field in continuous casting can be continuously inherited is considered, so that the defects generated at the upper position of the crystallizer can be reflected at the lower position, and the fact that the casting blank entity changes when the temperature and the ferrostatic pressure are loaded is considered, a casting blank solidification thermal coupling model in the crystallizer is established by using a multi-load step method, and under the condition that the taper and the air gap are considered, the temperature field, the blank shell thickness, the equivalent stress, the maximum principal stress and the width surface stress of each position of the casting blank are calculated according to the temperature field and the stress field simulated by ANSYS, so that the position where the casting blank cracks are most likely to be initiated and.
In fig. 4, (a) 175mm from the meniscus; (b) 350mm from the meniscus; (c) 525mm from the meniscus; (d) 700mm from the meniscus.
As can be seen from fig. 4 and 5, the temperature distribution cloud of the parison at different positions in the mold and the temperature change curve of each characteristic point match the temperature field calculation results of the previous study.
Referring to fig. 6, the shell thickness at each position of the cast slab is calculated as follows: the change process of the thickness of the blank shell in the crystallizer at each position of the beam blank.
In fig. 7, (a) 175mm from the meniscus; (b) 350mm from the meniscus; (c) 525mm from the meniscus; (d) 700mm from the meniscus.
Referring to fig. 7, the equivalent stress is calculated, and the cloud images of the equivalent stress distribution of the casting blank at the positions 175mm, 350mm, 525mm and 700mm away from the meniscus of the crystallizer are obtained. According to the equivalent stress change curve of each characteristic point, the equivalent stress at the web plate always shows an increasing trend, and reaches a maximum value at the rear half section of the crystallizer and is larger than the internal angle of the flange.
In fig. 8, (a) 175mm from the meniscus; (b) 350mm from the meniscus; (c) 525mm from the meniscus; (d) 700mm from the meniscus.
As can be seen from fig. 8 and 9, surface cracks of the casting slab are easily initiated and propagated in the middle of the mold, and the most likely position is the web, and then the R angle.
As can be seen from a comparison of fig. 10 and 11, the two figures verify the conclusion of the combined temperature field and the maximum principal stress: surface longitudinal cracks are easy to grow on the wide surface of a casting blank, particularly in the middle of a crystallizer; in conjunction with the temperature field, the most likely location to occur is at the web, followed by the R angle.
Step 2) research on macroscopic propagation of surface cracks of beam blank
It can be known from fig. 2 that the research and analysis of the macroscopic crack propagation of the beam blank surface is based on the later stage research performed in step 1, the temperature value and the stress value of the material at the position where the crack is easy to generate in step 1 are extracted, the gleable-3500 is used for testing the yield stress and the fracture toughness of the material at the corresponding temperature in the previous step to obtain the high-temperature thermophysical property parameters of the material at the corresponding temperature, and then based on the critical fracture toughness criterion index in fracture mechanics, the stress value extracted in step 1 is applied to the model of the pre-crack by using ABAQUS and the X-FEM method combined with the ABAQUS as the load force to perform the dynamic simulation of the initial crack propagation, so as to simulate the propagation condition of the surface crack at the web and.
FIG. 12 sub-model and pre-crack, (a) sub-model meshing; (b) and prefabricating surface cracks.
As can be seen in connection with fig. 12, crack modeling: the establishment of the matrix model is realized through a submodel module of ABAQUS, and the submodel technology not only can save the mechanical boundary conditions of the whole model, but also can ensure that the subsequent stress analysis is not influenced on the basis. As shown in fig. 12.
As can be seen from fig. 13, 14, 15, and 16, the crack propagation process at the web and the R-corner at the crack initiation site was simulated by the finite element propagation method.
Under the same material parameters and external force conditions, the surface longitudinal cracks are easier to expand, and the expansion amount is also maximum; the surface transverse crack is the least easy to expand and the expansion amount is the least; the direction can be deflected in the crack propagation process which forms an angle of 30 degrees and an angle of 60 degrees with the blank drawing direction, but the crack mainly propagates along the blank drawing direction, namely the crack longitudinally propagates; the surface crack with the same angle with the drawing direction has obviously larger expansion amount of the crack at the web plate than that at the R angle, which shows that the crack is more easily generated at the web plate.
Step 3) simulation of crack initiation and propagation in abnormal blank crystal
Referring to FIG. 3, the simulation of crack initiation and propagation in the preform crystal refers to the creation of a polycrystalline Voronoi map of the preform by MATLAB, then introducing the crystal model into ABAQUS to establish different forms, applying the X-FEM method in ABAQUS, based on the progressive decay in the mesoscopic damage mechanics as the criterion index, using the complete implicit stress iterative algorithm, and the physical parameters of the material at the corresponding temperature in the step 2 are utilized, and the stress and displacement values of the fracture tip unit calculated in the step 2 are extracted and are used as boundary conditions to be applied to the polycrystalline model, stress strain analysis of defect-free crystals, polycrystalline model analysis containing multiple cracks, polycrystalline model analysis containing different porosities and polycrystalline model analysis containing inclusions in different proportions are carried out in ABAQUS software, crack propagation simulation of polycrystalline models is carried out, and theoretical guidance is further provided for generation of macrocracks and process optimization.
As can be seen from fig. 17, the establishment of the polycrystal model is mainly realized by the MATLAB software programming, and a Voronoi diagram is drawn by using the relevant program.
It can be seen from fig. 18 how the load distribution of the polycrystalline model in ABAQUS is applied.
As can be seen from fig. 19, the stress-strain distributions of the grain boundary and the grain interior of the polycrystalline model are different in this example, and the stress-strain value at the grain boundary is significantly larger than that in the grain interior.
As can be seen from FIGS. 20 and 21, the direction of propagation of the cracks in the crystal is substantially the same as the direction of propagation of the macrocracks, and the cracks propagate in the direction perpendicular to the tensile stress, and the amount of propagation of the cracks in this direction is also the largest; the expansion amount of the crack at the grain boundary is obviously higher than that of the crack in the grain boundary; the angle of the crack and the tensile stress is irrelevant to the final propagation direction of the crack, and the influence of the crack on the crack propagation is mainly reflected on the time and the sequence of the crack propagation and the displacement of the final crack propagation.
As can be seen from fig. 22, the stress distribution of the air holes has a certain regularity, and the end portions of the air holes perpendicular to the direction of the tensile stress have a stress concentration; the deformation range of the polycrystalline model is enlarged due to the increase of the porosity; under different porosities, pores all expand and gather in the direction perpendicular to the tensile stress, and the localization of strain leads to the continuous polymerization and expansion of the pores, and the crack fracture tends to start from the direction.
As can be seen from fig. 23, stress concentration occurs at the inclusion sites at different inclusion rates, and the strain generated at the inclusion sites is minimized, so that cracks propagate along the inclusion direction, thereby causing material damage and fracture. The higher the inclusion rate, the more pronounced the inclusion stress concentration and the greater the deformation of the matrix around the inclusion.
It is understood from fig. 22 and 23 that the inclusions and pores have some influence on crack initiation and propagation, but the pores have a greater influence on crack initiation and propagation than the inclusions.
As can be seen from fig. 24, 25, and 26, the pull rate increases, the PHILSM value increases, the crack surface gradually increases, and the increase in the pull rate is favorable for crack propagation. This, as the pulling rate increases, increases the temperature of the surface of the cast slab at the same position of the crystallizer, so that the corresponding parameters of the cast slab material become worse, leading to cracks that are prone to crack.
As can be seen from fig. 24, 27, and 28, the crack propagation displacement function PHILSM value gradually increases with an increase in the degree of superheat, which is described as being advantageous for crack propagation.
As can be seen from fig. 25, 26, 27, and 28, the magnitude of the increase in the PHILSM value due to the increase in the pulling rate is greater than the magnitude of the increase in the PHILSM due to the increase in the superheat degree; it is shown that the increase of the pulling speed is more beneficial to the crack propagation of the casting blank relative to the increase of the superheat degree.
Macroscopic and microscopic crack simulation shows that the crack propagation is facilitated by inclusion and increase of porosity in the casting blank, and the crack propagation of the pores is higher than that of the inclusion; the increase of the pulling speed and the superheat degree are beneficial to the crack propagation of the casting blank, and the increase of the pulling speed is more beneficial to the crack propagation of the casting blank.
The embodiment is based on experimental simulation analysis and expert knowledge, closely contacts production practice, and provides a theoretical basis for the research of the germination and the propagation of the micro-cracks and the macrocracks of the continuous casting billets.
Simulating a temperature field and a stress field of the special-shaped blank in the crystallizer through ANSYS, thereby finding out the position where the casting blank crack is most likely to be initiated and expanded; then simulating the expansion behavior of the surface crack of the casting blank based on XFEM by adopting ABAQUS finite element software and an expansion finite element method and combining a high-temperature fracture experiment; and finally, the stress and the displacement of the crack tip unit obtained by the calculation in the previous step are used as boundary conditions to simulate the crystal crack initiation and propagation behaviors under the microscopic condition, so that a theoretical basis is provided for reducing the surface cracks of the casting blank, and the method is accurate, reliable, practical and convenient.
As will be apparent to those skilled in the art, many modifications and variations can be made in the present invention without departing from the spirit or scope of the invention, and it is intended that all such modifications and variations be included within the scope of the invention as defined in the following claims and their equivalents be interpreted in accordance with the teachings of the invention.
Claims (1)
1. The method for researching the germination and propagation of the micro-cracks and the macro-cracks of the continuous casting special-shaped blanks is characterized by comprising the following steps of:
1) thermal coupling analysis in the special-shaped blank continuous casting crystallizer is carried out, based on the stress genetic characteristic of a continuous casting blank shell, a casting blank solidification thermal coupling model in the crystallizer is established by a multi-load step method, under the condition of considering taper and air gap, according to a temperature field and a stress field simulated by ANSYS, the blank shell thickness, equivalent stress, maximum main stress and width surface stress of each position of the temperature field and the casting blank are calculated, and the position where the crack of the casting blank is most prone to initiation and expansion is found out;
2) performing macroscopic crack propagation research on the beam blank surface, testing the yield stress and the fracture toughness of the material at high temperature by using GLEEBLE-3500, and performing initial crack propagation dynamic simulation by using a large finite element analysis software ABAQUS and an X-FEM method combined with the ABAQUS on the basis of the theory of fracture mechanics to simulate the propagation condition of the surface crack at the beam blank web and the R angle in the crystallizer;
3) the method comprises the steps of simulating crack initiation and propagation in a special-shaped blank crystal, establishing a special-shaped blank polycrystalline model through MATLAB, and performing stress strain analysis of a defect-free crystal, polycrystalline model analysis containing a plurality of cracks, polycrystalline model analysis containing different porosities and polycrystalline model analysis containing inclusions in different proportions in ABAQUS software by utilizing a complete implicit stress iterative algorithm based on microscopic damage mechanics to simulate the crack propagation of the polycrystalline model.
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