CN111879226A - Furnace roller service life assessment method based on-site metallographic phase and roller surface deformation - Google Patents
Furnace roller service life assessment method based on-site metallographic phase and roller surface deformation Download PDFInfo
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Abstract
The invention relates to a furnace roller service life evaluation method based on-site metallographic phase and roller surface deformation, which comprises the steps of determining the trend that metallographic structures have creep holes to be connected into cracks or the appearance of the cracks as a metallographic phase rejection standard, and carrying out creep damage analysis based on the metallographic structures of the furnace roller to judge whether the metallographic structures reach the metallographic phase rejection standard or not; will be a threshold value L0Determining the deformation quantity as a deformation quantity failure standard, and judging whether the furnace roller is directly used continuously or not based on the deformation quantity L of the furnace roller; establishing an original furnace roller model or a furnace roller model after repair treatment according to the furnace roller deformation L; and S4, simulating to obtain a furnace roller service life prediction result based on the metallographic phase and the roller surface deformation based on the furnace roller creep material parameters corresponding to the metallographic phase. According to the furnace roller service life evaluation method, on-site metallographic detection and furnace roller deformation detection are taken as the basis, and the relation between microstructure change and performance caused by furnace roller creep damage and the relation between the furnace roller surface deformation and service life in actual production are fully considered.
Description
Technical Field
The invention relates to a method for evaluating the service life of an in-service furnace roller, in particular to a method for evaluating the service life of a furnace roller based on-site metallographic phase and roller surface deformation.
Background
Furnace rolls are important parts for transporting steel strip in a continuous annealing furnace, and the surface state of the roll surfaces thereof directly affects the quality of the produced steel strip. The furnace roller is rotated by a heat load of 800 ℃ or higher and a billet load, and is mechanically damaged (collision, abrasion, etc.) by the heated billet, and the operating conditions are severe, so SCH22(ZG40Cr25Ni20) austenitic heat-resistant steel is usually selected as the furnace roller material. The design life of the furnace roller can reach 10 ten thousand hours generally, but as the furnace roller is in a harsh operating environment with high temperature and high pressure for a long time, the microstructure of the furnace roller is degraded, the roller surface is deformed, the quality of rolled steel strips is poor, and serious economic loss in production is caused, so that the furnace roller has important significance for the regular life evaluation and failure detection of in-service furnace rollers on the normal operation of the annealing furnace.
The damage mechanism of the furnace roller is mainly creep damage, which can cause embrittlement of the furnace roller material, aggregation and coarsening of carbides in the microstructure of the material, sigma phase precipitation, and obvious reduction of elongation and impact power after high-temperature and normal-temperature fracture, so that the roller surface of the furnace roller deforms, the rolled steel strip has uneven surface, and economic loss in factory production is caused.
The furnace roller service life evaluation method provided in the prior art mainly adopts a parameter extrapolation method or a reference furnace tube metallographic evaluation method to evaluate the creep damage of the furnace roller, the furnace roller operation environment and failure mode in actual production are different from those of the furnace tube, and the furnace roller deformation is the main judgment basis of the furnace roller failure. Therefore, there is currently no standard effective method for in-service furnace roll life assessment.
The on-site metallographic detection technology is one of important nondestructive detection methods for the material degradation of the high-temperature component, and is mainly used for the high-temperature damage condition and creep damage evaluation of the component. In the traditional method, the damage degree of the material is qualitatively evaluated according to the microstructure characteristics of the material such as the appearance of carbide in a metallographic phase, creep holes or cracks and the like and the experience of a detector. In the prior art, a furnace roller metallographic evaluation method is not provided, furnace roller metallographic evaluation is mainly performed by referring to a furnace tube metallographic evaluation method, creep damage conditions need to be distinguished artificially and subjectively in the judgment process, and the failure mode and the operation environment of a furnace roller are not completely the same as those of a furnace tube, so that a more standard furnace roller service life evaluation method needs to be provided.
Disclosure of Invention
In order to more accurately and conveniently evaluate the damage state and the service life of the in-service furnace roller, the invention provides a furnace roller service life evaluation method based on-site metallographic phase and roller surface deformation grading.
The furnace roller service life evaluation method based on-site metallographic phase and roller surface deformation comprises the following steps: s1, determining the tendency that the metallographic structure has creep holes to be connected into cracks or the appearance of cracks as a metallographic scrapping standard, and carrying out creep damage analysis based on the metallographic structure of the furnace roller to judge whether the metallographic structure reaches the metallographic scrapping standard or not; s2, setting the threshold value L0Determining the deformation quantity as a deformation quantity failure standard, and judging whether the furnace roller is directly used continuously or not based on the deformation quantity L of the furnace roller; s3, establishing an original furnace roller model or a furnace roller model after repair treatment according to the furnace roller deformation L; and S4, simulating to obtain a furnace roller service life prediction result based on the metallographic phase and the roller surface deformation based on the furnace roller creep material parameters corresponding to the metallographic phase.
Preferably, step S1 includes: if the metallographic structure analysis of the furnace roller shows that the furnace roller has a tendency that creep holes are connected into cracks or has cracks, judging that the furnace roller reaches the scrapping standard, has exhausted service life and needs to be scrapped; and if the metallographic structure analysis of the furnace roller shows that the furnace roller has no tendency of cracking or has no cracks, judging that the furnace roller does not reach the rejection standard, has no service life, and can be continuously used.
Preferably, step S1 includes: and carrying out on-site film coating metallographic detection on the furnace roller to obtain metallographic structure picture information, and carrying out creep damage analysis based on the metallographic structure picture information.
Preferably, the outer surface of the furnace roller at the middle position in the shutdown state is ground and polished, and then on-site film coating metallographic detection is carried out, so that n groups of metallographic structure picture information P (1) … P (n) of the furnace roller at the middle position are obtained.
Preferably, n is 5. It should be understood that the purpose of the n sets of metallographic structure pictures is to take comprehensive analysis of the sets of pictures because the parts of the metallographic structure pictures may not have damage characteristics due to material creep damage. Therefore, the value of n is only taken as an example, and the number of samples is explicit.
Preferably, step S2 includes: if the deformation L of the furnace roller is less than the threshold value L0Judging that the deformation of the furnace roller is classified into A grade, and the deformation degree of the roller surface is smaller, so that the furnace roller can be continuously used; if the deformation L of the furnace roller is larger than the threshold value L0And judging that the deformation of the furnace roller is classified into B grade, the roller surface has serious deformation, the quality of the steel strip at the rolling position is poor, and the furnace roller cannot be used continuously or can be used continuously after repair treatment.
Preferably, step S2 includes: and (3) rotating the furnace roller frame on the lathe, measuring the deformation of the roller surface by using a dial indicator or a dial indicator to obtain the deformation of the roller surface of the furnace roller along the warp method, and taking the maximum value of the deformation of the roller surface of the furnace roller as the deformation L of the furnace roller.
Preferably, step S3 includes: if the furnace roller deformation level is A level and the furnace roller can be continuously used, establishing an original furnace roller model; and if the furnace roller deformation level is B level, the furnace roller cannot be used continuously or used after repair treatment, and then a repaired furnace roller model is established.
And selecting a Kachanov-Rabotnov injury equation (K-R equation for short) from the finite element constitutive equation.
Wherein:cfor creep strain, σ is the initial stress value, D is the damage variable, t is the furnace roll operating time, A, B, n, v,
The K-R equation parameters for the material were obtained by fitting uniaxial creep test data.
Preferably, step S4 includes: and selecting the K-R equation parameters of the material from the existing K-R equation parameters of the material corresponding to each metallographic structure according to the metallographic structure of the obtained material and the service temperature of the furnace roller. And carrying out finite element simulation according to the temperature of the furnace roller, the initial stress field and the K-R equation parameters of the material to obtain a residual life prediction result of the furnace roller.
According to the furnace roller service life evaluation method based on the on-site metallographic phase and the roller surface deformation, the metallographic phase is used as a waste judgment standard, the deformation is used as a grading standard, a finite element simulation method is adopted to obtain a furnace roller residual service life result, specifically, K-R equation parameters at corresponding temperature are determined according to an on-site metallographic phase detection result, a corresponding furnace roller model is established according to the furnace roller deformation detection, and the furnace roller residual service life result is obtained by adopting a finite element simulation method according to the service temperature and the stress of the furnace roller. The furnace roller service life evaluation method based on finite element simulation of on-site metallographic phase and roller surface deformation grading is a nondestructive detection method, does not need to cut a pipe or perform a persistence test again, has low detection and evaluation technical difficulty, higher efficiency and lower cost, and is convenient for on-site implementation. According to the furnace roller service life assessment method based on the on-site metallographic phase and the roller surface deformation, the furnace roller can be safely managed, and poor quality of a steel strip rolled by the furnace roller is avoided, so that the production loss can be greatly reduced, and the economic benefit is ensured.
Drawings
FIG. 1 is a typical metallographic structure picture of a furnace roller life evaluation method based on-site metallographic phase and roller surface deformation according to the present invention;
FIG. 2 is a metallographic structure photograph of example 1.
Detailed Description
The preferred embodiments of the present invention will be described in detail below with reference to the accompanying drawings.
The assessment method according to a preferred embodiment of the invention comprises the steps of determining the tendency of creep holes of the metallographic structure to be connected into cracks or the occurrence of cracks as the metallographic scrapping standard, and carrying out creep damage analysis on the metallographic structure of the furnace roller to judge whether the metallographic structure meets the metallographic scrapping standard or not. Specifically, the outer surface of the furnace roller at the middle position X in the shutdown state is ground and polished, then on-site film coating metallographic detection is carried out, n groups of metallographic structure picture information P (1) … P (n) of the furnace roller at the middle position X are obtained, typical metallographic structure information is shown in figure 1, the metallographic structure picture information P (1) … P (n) is analyzed, and according to typical metallographic characteristics, if the metallographic structure has a tendency that creep holes are connected into cracks or the cracks appear, the furnace roller is judged to reach the scrapping standard, the service life is exhausted, and scrapping treatment is needed; if the furnace roller has no tendency of cracking or no cracks, the furnace roller is judged to not reach the rejection standard, the service life is not exhausted, and the furnace roller can be continuously used.
The evaluation method according to a preferred embodiment of the invention comprises the step of setting a threshold value L0And determining the deformation failure standard, and judging whether the furnace roller is directly used continuously or not based on the deformation L of the furnace roller. Specifically, the furnace roller frame is rotated on a lathe, the deformation of the roller surface is measured by a dial indicator or a dial indicator to obtain the deformation of the roller surface of the furnace roller along the warp method, the maximum value of the deformation of the roller surface of the furnace roller is taken as the deformation L of the furnace roller, and if L is less than L, the deformation L is less than L0Judging that the furnace roller deformation grading D is A grade, and the roller surface deformation degree is smaller, so that the furnace roller can be continuously used; if L is greater than or equal to L0And judging that the furnace roller deformation grading D is grade B, the roller surface has serious deformation, and the quality of the rolled steel strip is poor and the steel strip cannot be used continuously or can be used continuously after being repaired.
The evaluation method according to a preferred embodiment of the present invention includes establishing a furnace roll creep model in combination with the amount of furnace roll surface deformation. Specifically, if the furnace roller deformation grading D is grade A, the furnace roller can be directly used continuously, and then an original furnace roller model is established; and if the furnace roller deformation grading D is B grade and cannot be used continuously or used after repair treatment, establishing a furnace roller model after cutting for a certain thickness and repair treatment. Selecting a K-R damage equation from a finite element constitutive equation, and expressing the K-R damage equation as follows:
wherein:cfor creep strain, σ is the initial stress value, D is the damage variable, t is the furnace roll operating time, A, B, n, v,
The K-R equation parameters for the material were obtained by fitting uniaxial creep test data.
The evaluation method according to the preferred embodiment of the invention comprises the step of carrying out finite element simulation life evaluation on the furnace roller according to the temperature section, the initial stress and the K-R equation parameters of the taken materials of the furnace roller. In this step, the following assumptions are made for convenience of calculation: the heat is regarded as steady heat conduction in the transfer process, and the friction between the strip steel and the furnace roller is neglected. Specifically, the finite element simulation temperature is the actual temperature of the furnace roller, the initial stress comprises the self weight of the furnace roller, the tension of the strip steel, the self weight of the strip steel and the temperature stress, and the K-R equation parameters of the material are selected from the existing parameters according to the service temperature of the furnace roller and the metallographic structure of the furnace roller. Carrying out finite element simulation according to the service temperature of the furnace roller, the initial stress state and the selected K-R equation parameters of the material to obtain the deformation L of the roller surface of the furnace roller model reaching the failure deformation L0The required time is taken as the remaining life of the furnace roller.
Example 1
The furnace rolls evaluated were 10 year in service furnace rolls. The furnace roller is made of SCH22 centrifugal casting austenitic stainless steel, the total length is 2000mm, and the service temperature is approximately 825 ℃. Firstly, the furnace roller to be evaluated is detected, the outer surface of the furnace roller at the middle position is selected for grinding, polishing and corroding, and the film covering is carried out for detection. Typical metallographic structure picture information P (1) … P (5) was examined at a magnification of 500 times for this group of positions 5 (i.e. positions 5 were chosen to ensure that the damage characteristics of the material could be observed), typical metallographic structure picture information P (i) being shown in fig. 2. Metallographic analysis is carried out on P (1) … P (5), and a metallographic picture is observed to find that the metallurgical grain boundary carbide of the furnace roller is seriously coarsened, a sigma phase (black phase) is greatly precipitated, creep holes are connected to form cracks, and the service life of the furnace roller is judged to be exhausted and needs to be scrapped.
And (3) rotating the furnace roller frame on a lathe, measuring the deformation of the roller surface by using a dial indicator or a dial indicator to obtain the deformation of the roller surface of the furnace roller along the warp method, and taking the maximum value of the deformation of the roller surface of the furnace roller as the deformation L of the furnace roller. And selecting the maximum value of the deformation of the furnace roller as the deformation L of the furnace roller, wherein L is 0.9 mm. The furnace roller deformation L is more than or equal to the furnace roller failure deformation L0(this value is determined by measuring the deformation of the failed furnace roll), and therefore, it is judged that the furnace roll deformation is classified as class B and cannot be used continuously or after being repaired.
Grading the furnace roller into B grade according to the deformation of the furnace roller, and establishing a furnace roller model after cutting to a certain thickness and repairing; according to the metallurgical evaluation of the furnace roller, the furnace roller can reach the rejection standard, and K-R equation parameters of a material corresponding to a failed metallurgical phase at the temperature of 825 ℃ are selected, wherein the specific parameters are shown in Table 1. And carrying out finite element simulation according to the service temperature, the initial stress state and the K-R equation parameters of the material. The simulation result shows that the furnace roller surface deformation L reaches the failure deformation L under the service temperature and the service stress field0The time of the method is extremely short, the production requirement is not met, the metallographic structure of the product reaches the rejection standard, the service life is exhausted, and the product needs to be rejected.
TABLE 1
The fact that the furnace roller has deformed the roller surface of the furnace roller during the continuous use process leads to the uneven belt at the rolling position, thereby illustrating the correctness and the reliability of the invention.
The above embodiments are merely preferred embodiments of the present invention, which are not intended to limit the scope of the present invention, and various changes may be made in the above embodiments of the present invention. All simple and equivalent changes and modifications made according to the claims and the content of the specification of the present application fall within the scope of the claims of the present patent application. The invention has not been described in detail in order to avoid obscuring the invention.
Claims (10)
1. A furnace roller service life assessment method based on-site metallographic phase and roller surface deformation is characterized by comprising the following steps:
s1, determining the tendency that the metallographic structure has creep holes to be connected into cracks or the appearance of cracks as a metallographic scrapping standard, and carrying out creep damage analysis based on the metallographic structure of the furnace roller to judge whether the metallographic structure reaches the metallographic scrapping standard or not;
s2, setting the threshold value L0Determining the deformation quantity as a deformation quantity failure standard, and judging whether the furnace roller is directly used continuously or not based on the deformation quantity L of the furnace roller;
and S3, establishing an original furnace roller model or a furnace roller model after repair treatment according to the furnace roller deformation L.
And S4, simulating to obtain a furnace roller service life prediction result based on the metallographic phase and the roller surface deformation based on the furnace roller creep material parameters corresponding to the metallographic phase.
2. The furnace roller life evaluation method according to claim 1, wherein step S1 includes: if the metallographic structure analysis of the furnace roller shows that the furnace roller has a tendency that creep holes are connected into cracks or has cracks, judging that the furnace roller reaches the scrapping standard, has exhausted service life and needs to be scrapped; and if the metallographic structure analysis of the furnace roller shows that the furnace roller has no tendency of cracking or has no cracks, judging that the furnace roller does not reach the rejection standard, has no service life, and can be continuously used.
3. The furnace roller life evaluation method according to claim 1, wherein step S1 includes: and carrying out on-site film coating metallographic detection on the furnace roller to obtain metallographic structure picture information, and carrying out creep damage analysis based on the metallographic structure picture information.
4. The method for evaluating the life of a furnace roller according to claim 3, wherein the outer surface of the furnace roller at the intermediate position in the shutdown state is ground and polished, and then on-site film-coating metallographic examination is performed to obtain n sets of metallographic structure picture information P (1) … P (n) of the furnace roller at the intermediate position.
5. The furnace roller life evaluation method according to claim 4, wherein n is 5.
6. The furnace roller life evaluation method according to claim 1, wherein step S2 includes: if the deformation L of the furnace roller is less than the threshold value L0Judging that the deformation grading D of the furnace roller is A grade, and the deformation degree of the roller surface is smaller, so that the furnace roller can be continuously used; if the deformation L of the furnace roller is larger than the threshold value L0And judging that the deformation grading D of the furnace roller is B grade, the roller surface of the furnace roller is seriously deformed, and the quality of the steel strip at the rolling position is poor, so that the steel strip can not be continuously used or can not be continuously used after repair treatment.
7. The furnace roller life evaluation method according to claim 6, wherein step S2 includes: and (3) rotating the furnace roller frame on the lathe, measuring the deformation of the roller surface by using a dial indicator or a dial indicator to obtain the deformation of the roller surface of the furnace roller along the warp method, and taking the maximum value of the deformation of the roller surface of the furnace roller as the deformation L of the furnace roller.
8. The furnace roller life evaluation method according to claim 1, wherein step S3 includes: and aiming at the measured furnace roller deformation L, establishing an original furnace roller model or a furnace roller model after repair treatment.
9. The method for evaluating the life of a furnace roller according to claim 8, wherein the finite element model is a Kachanov-Rabotnov damage constitutive equation (K-R equation for short) which is:
wherein:cfor creep strain, σ is the initial stress value, D is the damage variable, t is the furnace roll operating time, A, B, n, v,
Obtained by fitting uniaxial creep test data for the material parameters of the K-R equation.
10. The furnace roller life evaluation method according to claim 1, wherein step S4 includes: and selecting the material K-R equation parameters from the furnace roller material K-R equation parameters corresponding to the existing metallographic structure according to the obtained furnace roller metallographic structure information and the furnace roller service temperature. And simulating to obtain a furnace roller service life prediction result under the corresponding metallographic phase and the furnace roller deformation according to the temperature section of the furnace roller, the initial stress field and the K-R equation parameters of the material.
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| CN112883604A (en) * | 2021-01-21 | 2021-06-01 | 西北工业大学 | Method for determining creep strength of nickel-based single crystal blade at different positions |
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