CN113640165B - Method and system for evaluating comprehensive performance of remanufactured hot-rolled working roll - Google Patents
Method and system for evaluating comprehensive performance of remanufactured hot-rolled working roll Download PDFInfo
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- CN113640165B CN113640165B CN202110916732.5A CN202110916732A CN113640165B CN 113640165 B CN113640165 B CN 113640165B CN 202110916732 A CN202110916732 A CN 202110916732A CN 113640165 B CN113640165 B CN 113640165B
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N3/00—Investigating strength properties of solid materials by application of mechanical stress
- G01N3/56—Investigating resistance to wear or abrasion
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G01M13/00—Testing of machine parts
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N25/00—Investigating or analyzing materials by the use of thermal means
- G01N25/20—Investigating or analyzing materials by the use of thermal means by investigating the development of heat, i.e. calorimetry, e.g. by measuring specific heat, by measuring thermal conductivity
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2203/00—Investigating strength properties of solid materials by application of mechanical stress
- G01N2203/0001—Type of application of the stress
- G01N2203/0005—Repeated or cyclic
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2203/00—Investigating strength properties of solid materials by application of mechanical stress
- G01N2203/0058—Kind of property studied
- G01N2203/0069—Fatigue, creep, strain-stress relations or elastic constants
- G01N2203/0075—Strain-stress relations or elastic constants
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2203/00—Investigating strength properties of solid materials by application of mechanical stress
- G01N2203/02—Details not specific for a particular testing method
- G01N2203/022—Environment of the test
- G01N2203/0222—Temperature
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/30—Computing systems specially adapted for manufacturing
Abstract
The invention relates to the field of mechanical testing, in particular to a method and a system for evaluating comprehensive performance of a remanufactured hot-rolled working roll. The method comprises the following steps: s1: preprocessing the test roller to meet simulation conditions of real working conditions; the pre-processing process includes a heat treatment process and a surface processing process. S2: the workpiece is subjected to simulated rolling through the test roller, so that an equivalent test force p in the simulated rolling process is obtained t Equivalent test speed n t Loading temperature T of loading roller t And a coolant injection pressure P t . S3: and taking the parameter value obtained in the previous step as a test parameter of a comprehensive performance evaluation test to obtain a comprehensive performance evaluation result of the hot rolling working roll. The hot rolling working roll comprehensive performance evaluation system comprises: the system comprises a model generation module, an error comparison module, a test parameter acquisition module and a performance test control module. The invention solves the problem that the existing remanufactured hot-rolled working roll abrasion and thermal fatigue comprehensive test method cannot give consideration to both data accuracy and cost control.
Description
Technical Field
The invention relates to the field of mechanical testing, in particular to a method and a system for evaluating comprehensive performance of a remanufactured hot-rolled working roll.
Background
The hot rolling working rolls are the main working components in the rolling processing equipment; the hot rolling working rolls are subjected to thermal stress caused by expansion of materials, residual stress generated in the manufacturing process and load caused by mechanical stress generated by extrusion of the materials in the rolling process at the same time in the hot rolling process. The three loads act together in the actual production process, and alternating stress is generated on the surface of the hot rolling working roll, so that the hot rolling working roll is subjected to thermal abrasion and thermal fatigue damage. These two forms of damage can affect each other, eventually leading to failure of the hot rolled work rolls and loss of service value.
At present, the remanufactured hot rolling working roll is mainly subjected to repair production by technologies such as laser cladding, plasma cladding and the like. Cladding layers are typically required to be subjected to a combination of hot roll wear and thermal fatigue testing, with the results of the performance testing being able to assist in the improvement of the hot roll manufacturing/remanufacturing process. The existing research method for the comprehensive performance of the abrasion and the thermal fatigue of the hot rolling working roll mainly comprises two types: (1) full-size testing with a true hot rolling mill; (2) Performance tests based on disc-type twin-roll thermal wear testing machine. The former belongs to full-true simulation test, and has the advantages of good test effect and high accuracy of test data. However, the test method can affect the production plan, and has high test cost and long period. And equipment such as an online nondestructive testing system and the like are required to be installed in a real rolling mill, and the problems of high development, installation and maintenance difficulty, high cost and the like exist. The latter is tested on a special testing machine, so that the problems that the former affects the production of equipment and the testing cost is high can be solved. However, the working parameters in the real hot rolling process cannot be obtained in the test process, the difference between the test conditions and the boundary conditions of the real hot rolling working rolls cannot be fully considered, the load born by the test working rolls in the test is greatly different from that born by the real hot rolling working rolls, and the comprehensive performance of the abrasion and the thermal fatigue of the working rolls cannot be accurately evaluated.
Disclosure of Invention
Based on the above, it is necessary to solve the problem that the existing comprehensive test method for the abrasion and the thermal fatigue of the hot rolling working roll cannot achieve both the accuracy of data and the control of test cost; providing a method and a system for evaluating comprehensive performance of a remanufactured hot rolling working roll; the method and the system complete full-true simulation of the real working condition on the disc type twin-roll thermal wear testing machine, and obtain more accurate test data.
The invention provides a remanufactured hot-rolled working roll comprehensive performance evaluation method, which is used for evaluating the performance of a hot-rolled working roll generated by a remanufacturing process and specifically comprises the following steps of:
s1: preprocessing the test roller to meet the simulation condition that the test roller can achieve the real working condition of the hot rolling working roller; the pre-processing process includes a heat treatment process and a surface processing process.
S2: simulation of a workpiece by a test rollThe rolling, the simulated rolling process is used for simulating the real hot rolling process of the hot rolling working roll, so as to obtain the equivalent test force p in the simulated rolling process t Equivalent test speed n t Loading temperature T of loading roller t And a coolant injection pressure P t The method comprises the steps of carrying out a first treatment on the surface of the The process is specifically as follows:
S21: according to the analysis result of the test roller under the actual working condition, the boundary condition of the test roller is divided into five types of areas along the circumferential direction, namely an engagement area, a radiation area, a water baffle cooling area, a jet cooling area and an air cooling area.
S22: and constructing heat exchange boundary conditions of the various types of areas based on the judgment result of the heat transfer types of the various different types of areas on the test roller.
S23: setting an initial value n of a test rotating speed t0 And an initial value P of the coolant injection pressure t0 Performing simulated rolling to obtain values of all test parameters in heat exchange boundary conditions in the simulated rolling process, and calculating equivalent test force p in the current simulated rolling process t And equivalent test speed n t At the same time, the loading temperature T of the loading roller is obtained t And a coolant injection pressure P t 。
S24: calculating heat exchange coefficients of different types of areas in the test roller, and applying equivalent test force p t Equivalent test speed n t Loading temperature T of loading roller t And a coolant injection pressure P t Substituting into a heat exchange boundary condition; and then a temperature analysis model and a stress-strain analysis model of the test roller under the current working condition are constructed.
S25: and analyzing the temperature gradient and circumferential stress distribution of the test roll surface within the range of 0-5mm according to the constructed temperature analysis model and stress-strain analysis model.
S26: obtaining analysis results of temperature gradient and circumferential stress distribution of a real hot rolling working roll under the same working condition; comparing the temperature gradient of the test roll with the analysis result of the circumferential stress distribution of the real hot rolling working roll, and calculating the extreme value error of the test roll and the real hot rolling working roll; and making a judgment according to the result of the extreme value error:
(1) Current electrodeThe value error is less than or equal to 5 percent, and the test roller is considered to meet the simulation requirement of the real working condition; at this time, an equivalent test force p obtained in the simulated rolling process under the current working condition is obtained t Equivalent test speed n t Loading temperature T of loading roller t And a coolant injection pressure P t Specific values of (2);
(2) When the extreme value error is more than 5%, the test roller is considered to not reach the simulation requirement of the real working condition; at this time, the process returns to step S23; adjusting the initial value n of the test rotating speed t0 And an initial value P of the coolant injection pressure t0 ，
Re-executing the simulated rolling process; until the simulation requirement of the real working condition is reached.
S3: equivalent test force p obtained in the previous step t Equivalent test speed n t Loading temperature T of loading roller t And a coolant injection pressure P t And (3) performing abrasion and thermal fatigue comprehensive performance test on the test roller as test parameters of the comprehensive performance evaluation test to obtain a comprehensive performance evaluation result of the test roller, wherein the result is a comprehensive performance evaluation result of the working roller under a real working condition.
The comprehensive performance evaluation method for the remanufactured hot-rolled working roll provided by the invention considers the influence of three loads of thermal stress caused by thermal expansion in the hot rolling process, residual stress generated in the manufacturing process and mechanical stress generated by strip extrusion in the rolling process on the damage of the working roll. The simulation of the actual working condition of the hot rolling working roll is realized by equivalent calculation and analysis of test parameters and by improving the application mode of the disc type abrasion tester.
The method provided by the invention can be combined with the conclusion of numerical calculation and equivalent test, so that the full true simulation of the real working condition is realized, and the effect of completely simulating the real processing working condition on the testing machine is realized. And further, the comprehensive performance evaluation process is separated from real processing equipment, and the technical effect of similar evaluation conclusion is achieved. Effectively reduces the test period and cost, and improves the accuracy of the comprehensive performance evaluation of the wear and thermal fatigue of the remanufactured hot-rolled working roll.
As a further improvement of the invention, in the step S1, the heat treatment process comprises oil quenching treatment and tempering treatment twice according to the time sequence, and after the heat treatment process is completed, the surface hardness of the test roller is not less than 60HRC at room temperature; after the surface processing process is finished, the surface roughness Ra of the test roll is between 0.8 and 1.6 mu m.
As a further improvement of the invention, the simulated rolling process of the step S2 and the abrasion and thermal fatigue comprehensive performance test process of the step S3 are completed in a disc type twin-roll thermal abrasion tester.
As a further improvement of the invention, in the simulated rolling process of the step S2, the friction coefficient between the workpiece and the test piece reaches the minimum value on the basis of ensuring that the biting condition is met by adjusting the concentration of the cooling liquid; the minimum value is defined as the test friction coefficient, which ranges from 0.15 to 0.4.
As a further improvement of the present invention, in step S23, the equivalent test force p t The calculation formula of (2) is as follows:
in the above formula, p is the hot rolling force, and B is the width of the workpiece; l is the contact arc length of the test roll and the workpiece, ρ is the comprehensive curvature radius of the test piece and the loading roll, b is the roll width of the test roll, μ 1 Sum mu 2 Poisson ratio of test piece and loading roller at test temperature, E 1 And E is 2 The modulus of elasticity of the test roller and the loading roller at the test temperature, respectively.
As a further improvement of the invention, the equivalent test rotation speed n t The calculation formula of (2) is as follows:
in the above formula, n is the rotating speed of the test roller, l is the contact arc length of the test roller and the workpiece, l t For the contact arc length of the test roller and the loading roller, h c The average heat exchange coefficient of the biting area of the hot rolling working roll and the workpiece is h t The average heat exchange coefficient of the nip area of the test roll and the loading roll.
As a further improvement of the invention, in the abrasion and thermal fatigue comprehensive performance test process of the step S3, the crack condition of the surface of the test roller is monitored on line in real time through nondestructive testing equipment until the abrasion and thermal fatigue comprehensive performance test is stopped when the crack with the preset length is detected on the surface of the test roller.
As a further improvement of the invention, the nondestructive testing equipment monitors the surface cracks of the test roller by a non-contact scanning method; the scanning frequency of the nondestructive testing equipment is larger than the rotating frequency of the test roller, and the detection precision of the nondestructive testing equipment is smaller than 0.5mm.
The invention also comprises a remanufactured hot-rolled working roll comprehensive performance evaluation system, wherein the remanufactured hot-rolled working roll comprehensive performance evaluation system adopts the remanufactured hot-rolled working roll comprehensive performance evaluation method, simulates the real working condition of a hot-rolled working roll, and accurately evaluates the comprehensive performance of a test roll produced by a remanufacturing process; the hot rolling working roll comprehensive performance evaluation system comprises: the system comprises a model generation module, an error comparison module, a test parameter acquisition module and a performance test control module.
The model generation module is used for constructing a temperature analysis model and a stress-strain model of the test roller according to test parameters for simulating the rolling process. The model generation module comprises a type region classification unit, an initial value updating unit and a data analysis unit. The type area classification unit is used for dividing boundary conditions of the test roller into five types of areas along the circumferential direction according to analysis results of the test roller under actual working conditions, wherein the five types of areas are respectively an occlusion area, a radiation area, a water baffle cooling area, a jet cooling area and an air cooling area; and constructing heat exchange boundary conditions of each type of region based on the judgment result of the heat transfer type of each different type of region on the test roller. The initial value updating module is used for initializing the initial value n of the test rotating speed in the simulated rolling process before the test starts or when the extreme value error between the result of each simulated rolling and the real working condition does not meet the requirement t0 And an initial value P of the coolant injection pressure t0 Automatic updating. The data analysis unit is used for performing simulated rolling after the initial value updating module completes the numerical value updating, obtaining the numerical value of each test parameter in the heat exchange boundary condition of the simulated rolling process, and calculating the equivalent test force p in the current simulated rolling process t And equivalent test speed n t At the same time, the loading temperature T of the loading roller is obtained t And a coolant injection pressure P t The method comprises the steps of carrying out a first treatment on the surface of the And then equivalent test force p t Equivalent test speed n t Loading temperature T of loading roller t And a coolant injection pressure P t Substituting the four values into a heat exchange boundary condition, and calculating heat exchange coefficients of different types of areas in the test roller; and then a temperature analysis model and a stress-strain analysis model of the test roller under the current working condition are built.
The error comparison module is used for acquiring the analysis result of the temperature gradient and circumferential stress distribution of the test roller in the simulation processing process, which is obtained in the model generation module; the analysis results of the temperature gradient and circumferential stress distribution of the real hot rolling working roll under the same working condition are obtained; and then the extreme value errors of the two are calculated.
The test parameter acquisition module is used for acquiring an equivalent test force p under the current working condition when the extreme value error calculation result output by the error comparison module is less than or equal to 5 percent t Equivalent test speed n t Loading temperature T of loading roller t And a coolant injection pressure P t And four values were used as test parameters in the comprehensive performance evaluation test.
The performance test control module is used for controlling the abrasion and thermal fatigue comprehensive performance test process of the test roller by taking the numerical value output by the test parameter acquisition module as the numerical value of the test parameter in the comprehensive performance evaluation test; and further obtaining the comprehensive performance evaluation result of the test roller, wherein the result is the comprehensive performance evaluation result of the working roller under the real working condition.
The invention provides a remanufacturing hot rolling working roll comprehensive performance evaluation system, which is an automatic control system for implementing the comprehensive performance evaluation method. The system based on the automatic programming can be installed in the existing disc type twin-roll thermal wear testing machine to evaluate and test the performance of each type of working roll. And the automatic test is realized, and the evaluation conclusion is rapidly obtained. And the efficiency and the accuracy of the comprehensive performance evaluation of the hot rolling working rolls are improved.
As a further improvement of the invention, the comprehensive performance evaluation system of the hot rolling working roll is applied to a disc type double-roll hot wear testing machine; in the wear and thermal fatigue comprehensive performance test, the test roll is used for simulating three loads, namely thermal stress caused by expansion born by a working roll in actual hot rolling, residual stress generated in the manufacturing process and mechanical stress generated by strip extrusion in the rolling process.
The method and the system for evaluating the comprehensive performance of the remanufactured hot-rolled working roll have the following beneficial effects:
1. the technical scheme provided by the invention simultaneously considers the influence of three loads, namely thermal stress caused by thermal expansion in the hot rolling process, residual stress generated in the manufacturing process and mechanical stress generated by strip extrusion in the rolling process, on the damage of the working roller. And the 'full true simulation' of the hot rolling working roll to the real working condition is realized through the equivalent calculation and analysis of the test parameters and the improvement and application of the disc type abrasion tester.
2. The whole set of method and system provided by the invention combine the results of numerical calculation and equivalent tests, improves the accuracy of the comprehensive performance evaluation of the wear and thermal fatigue of the hot rolling working roll, and effectively reduces the test period and cost.
3. The experimental method can evaluate the comprehensive performances of wear and thermal fatigue of the hot rolling working rolls in various working conditions and different times, and has wide adaptability. It is concluded that basic test data can be provided for the development of the manufacturing/remanufacturing process of the hot rolled work rolls, the improvement of the comprehensive performance of wear resistance and thermal fatigue resistance, and the life prediction.
Drawings
FIG. 1 is a flowchart showing a method for evaluating the overall performance of a remanufactured hot rolled work roll according to example 1 of the present invention;
FIG. 2 is a program flow chart showing the overall performance evaluation method of the remanufactured hot rolled work roll according to example 1 of the present invention.
FIG. 3 is a schematic diagram showing the boundary conditions of a real remanufactured hot rolled work roll under actual conditions in example 1 of the present invention;
FIG. 4 is a schematic diagram showing the boundary conditions of the test roll in example 1 of the present invention;
FIG. 5 is a graph showing the radial distribution of the temperature gradient at the nip exit of the hot roll working roll and the test roll according to example 1 of the present invention;
FIG. 6 is a graph showing a comparative radial distribution of thermal stress gradients at the nip exit of a hot roll work roll and a test roll according to example 1 of the present invention;
FIG. 7 is a system topology diagram of a remanufactured hot rolled work roll integrated performance evaluation system according to example 2 of the present invention.
Marked in the figure as:
1. hot rolling a working roll; 2. hot rolling a supporting roller; 3. a workpiece; 4. hot rolling the water baffle; 5. a hot rolling cooling liquid nozzle; 6. a loading roller; 7. a test roller; 8. testing a water baffle; 9. test cooling liquid nozzle.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "or/and" as used herein includes any and all combinations of one or more of the associated listed items.
Example 1
The present embodiment provides a remanufactured hot rolled work roll comprehensive performance evaluation method for evaluating performance of a hot rolled work roll generated through a remanufacturing process, as shown in fig. 1, specifically including the steps of:
s1: preprocessing the test roller to meet the simulation condition that the test roller can achieve the real working condition of the hot rolling working roller; the test rolls are test models relative to the actual hot rolled work rolls. The pre-processing process includes a heat treatment process and a surface processing process. In this example, the test roll was selected from remanufactured rolls generated by a plasma cladding process.
The heat treatment process comprises oil quenching treatment and tempering treatment twice according to time sequence, and after the heat treatment process is finished, the surface hardness of the test roller is not less than 60HRC at room temperature; after the surface processing technology is finished, the surface roughness Ra of the test roll is between 0.8 and 1.6 mu m. S2: the simulated rolling is carried out on the workpiece through the test roll, and the simulated rolling process is used for simulating the actual hot rolling process of the hot rolling working roll. In the step, the friction coefficient between the workpiece and the test piece reaches the minimum value on the basis of ensuring that the biting condition is met by adjusting the concentration of the cooling liquid; the minimum value is defined as the test friction coefficient, which ranges from 0.15 to 0.4. The equivalent test force p can be obtained in the simulated rolling process t Equivalent test speed n t Loading temperature T of loading roller t And a coolant injection pressure P t The method comprises the steps of carrying out a first treatment on the surface of the The process is specifically as follows:
s21: according to the analysis result of the test roller under the actual working condition, the boundary condition of the test roller is divided into five types of areas along the circumferential direction, namely an engagement area, a radiation area, a water baffle cooling area, a jet cooling area and an air cooling area.
S22: and constructing heat exchange boundary conditions of the various types of areas based on the judgment result of the heat transfer types of the various different types of areas on the test roller.
S23: setting an initial value n of a test rotating speed t0 And an initial value P of the coolant injection pressure t0 Performing simulated rolling to obtain values of all test parameters in heat exchange boundary conditions in the simulated rolling process, and calculating equivalent test force p in the current simulated rolling process t And equivalent test speed n t At the same time, the loading temperature T of the loading roller is obtained t And a coolant injection pressure P t 。
In this embodiment, the equivalent test force p t The calculation formula of (2) is as follows:
in the above formula, p is the hot rolling force, and B is the width of the workpiece; l is the contact arc length of the test roll and the workpiece, ρ is the comprehensive curvature radius of the test piece and the loading roll, b is the roll width of the test roll, μ 1 Sum mu 2 Poisson ratio of test piece and loading roller at test temperature, E 1 And E is 2 The modulus of elasticity of the test roller and the loading roller at the test temperature, respectively.
Equivalent test speed n t The calculation formula of (2) is as follows:
in the above formula, n is the rotating speed of the test roller, l is the contact arc length of the test roller and the workpiece, l t For the contact arc length of the test roller and the loading roller, h c The average heat exchange coefficient of the biting area of the hot rolling working roll and the workpiece is h t The average heat exchange coefficient of the nip area of the test roll and the loading roll.
S24: calculating heat exchange coefficients of different types of areas in the test roller, and applying equivalent test force p t Equivalent test speed n t Loading temperature T of loading roller t And a coolant injection pressure P t Substituting into a heat exchange boundary condition; and then a temperature analysis model and a stress-strain analysis model of the test roller under the current working condition are constructed.
S25: and analyzing the temperature gradient and circumferential stress distribution of the test roll surface within the range of 0-5mm according to the constructed temperature analysis model and stress-strain analysis model.
S26: obtaining analysis results of temperature gradient and circumferential stress distribution of a real hot rolling working roll under the same working condition; comparing the temperature gradient of the test roll with the analysis result of the circumferential stress distribution of the real hot rolling working roll, and calculating the extreme value error of the test roll and the real hot rolling working roll; and making a judgment according to the result of the extreme value error:
(1) When the extreme value error is less than or equal to 5%, the test roller is considered to reach the simulation requirement of the real working condition; at this time, an equivalent test force p obtained in the simulated rolling process under the current working condition is obtained t Equivalent test speed n t Loading temperature T of loading roller t And a coolant injection pressure P t Specific values of (2);
(2) When the extreme value error is more than 5%, the test roller is considered to not reach the simulation requirement of the real working condition; at this time, the process returns to step S23; adjusting the initial value n of the test rotating speed t0 And an initial value P of the coolant injection pressure t0 ，
Re-executing the simulated rolling process; until the simulation requirement of the real working condition is reached.
S3: equivalent test force p obtained in the previous step t Equivalent test speed n t Loading temperature T of loading roller t And a coolant injection pressure P t And (3) performing abrasion and thermal fatigue comprehensive performance test on the test roller as test parameters of the comprehensive performance evaluation test to obtain a comprehensive performance evaluation result of the test roller, wherein the result is a comprehensive performance evaluation result of the working roller under a real working condition.
The comprehensive performance evaluation test monitors the crack condition of the surface of the test roller on line in real time through nondestructive testing equipment until the abrasion and thermal fatigue comprehensive performance test is stopped when the crack with the preset length is detected on the surface of the test roller.
The nondestructive testing equipment monitors the surface cracks of the test roller through a non-contact scanning method; the scanning frequency of the nondestructive testing equipment is larger than the rotating frequency of the test roller, and the detection precision of the nondestructive testing equipment is smaller than 0.5mm.
In this embodiment, the simulated rolling process in step 2 and the abrasion and thermal fatigue comprehensive performance test process in step S3 are both completed in a disc-type twin-roll thermal abrasion tester.
The embodiment also performs test verification on the provided comprehensive performance evaluation method of the remanufactured hot-rolled working roll. The test procedure was completed in a disc twin roll thermal wear tester. A method for evaluating the overall performance of a remanufactured hot rolled work roll in this embodiment will be described in detail with reference to the program flow chart of fig. 2.
1. Pretreatment of test rolls
Before the comprehensive performance test starts, the test requirements are met in order to keep the basic performance of the product because the roller is manufactured again; the test rolls to be evaluated need to be pretreated first. In the pretreatment process, firstly, carrying out high-temperature quenching and tempering heat treatment on the test roller; the quenching treatment adopts an oil quenching process at 1100-1200 ℃. The tempering treatment temperature is 550 ℃, the tempering process in the pretreatment process comprises two times of 1 hour each, and the surface hardness of the test roller after the heat treatment is finished is not less than 60HRC at room temperature.
After the heat treatment is finished, the surface finish machining is also required to be carried out on the test roller, and the roughness of the surface of the test roller is mainly changed in the finish machining process; and further, the test roller can meet the biting condition used in the hot rolling process, and the slipping between the hot rolling working roller and the workpiece is avoided. Meanwhile, the friction coefficient of the test roll surface should be as small as possible, and in general, the roughness Ra of the test roll surface is preferably in the range of 0.8 to 1.6. Mu.m.
In general, the hot rolling lubrication condition is a key influencing factor of roller wear, and the larger the friction coefficient is, the more serious the wear of the hot rolling working roller is, and the service life is reduced. In order to solve the problem, in this embodiment, the improvement of the lubrication condition is achieved by changing the proportion of the lubrication liquid, the friction coefficient after lubrication is far smaller than that of water cooling or dry friction, and the service life of the roller can be prolonged. The coefficient of friction of the test rolls in the performance test can be reduced by increasing the percentage of solvent in the coolant over a range of concentrations in the test. Meanwhile, in order to meet different biting conditions of hot rolling, in the embodiment, the test friction coefficient reaches 0.15-0.4 by adjusting the percentage of the cooling liquid solvent. This is the best parameter determined empirically.
2. Determination of test parameters
In the embodiment, the real hot rolling process of the hot rolling working roll is simulated on the disc type twin-roll hot wear testing machine, so that the test parameters in the comprehensive performance testing process are required to be determined according to the real data of the real hot rolling process, and the optimal simulation effect is achieved. Wherein, the real data in the actual hot rolling process is acquired in advance. In order to make the explanation process clearer, a comparative analysis and description will be made below of a real hot rolling process and a simulated rolling process of the test rolls in this embodiment on a disk type twin roll hot wear tester.
In the embodiment, the boundary conditions of the real hot rolling working roll and the test roll in the rolling process are analyzed first, and the boundary conditions can be used for constructing a thermal analysis model and a stress-strain model of the real hot rolling working roll or the test roll in the processing process. In the reprocessing process, the heat conduction and heat dissipation conditions of different areas of the hot rolling working roll or the test roll are different, and the stress conditions are also continuously changed, so that the boundary conditions of all areas are also continuously changed along the circumferential direction of the hot rolling working roll or the test roll. The specific process can be broadly divided into 5 main types of zones, including a nip zone, a radiant zone, a water baffle cooling zone, a spray cooling zone, and an air cooling zone, respectively. Wherein the occlusion area is an area contacted with the high-temperature workpiece or the loading roller; the radiation area is an area which is thermally radiated by the high-temperature workpiece or the loading roller; the water baffle cooling area is an area where the water baffle stores cooling liquid; the spray cooling area is an area sprayed by the cooling liquid nozzle; the air cooling zone is the area in contact with the air.
Based on the judgment of the heat generation type of each type of region in each condition, the heat exchange boundary condition of each different type of region can be constructed.
Taking 1780mm hot finishing mill group F4 stand work rolls (i.e., the actual hot rolling work rolls in this example) as an example, the equipment parameters are shown in Table 1:
table 1: operating parameters of the Hot Rolling Unit in the present embodiment
Wherein, for the hot rolling working rolls, different regions on the hot rolling working rolls can be classified as shown in fig. 3.
The relative positions between the hot rolling work rolls 1, the hot rolling backup rolls 2, the work pieces 3, the hot rolling water deflector 4 and the hot rolling coolant nozzles 5 are shown in the drawing of fig. 3, respectively. In combination with the distribution positions of the hot-rolling backup roll 2, the work piece 3, the hot-rolling water deflector 4 and the hot-rolling coolant nozzle 5, the respective area ranges of the hot-rolling work roll 1 in the circumferential direction are specifically classified into: according to the anticlockwise direction, the A-B interval is an occlusion area, the B-C and I-A intervals are radiation areas, the C-D and H-I intervals are water baffle cooling areas, the D-E and G-H intervals are jet cooling areas, and the E-F and F-G intervals are air cooling areas.
Based on the classified different region types of the hot rolling working rolls and the real hot rolling working parameters, the heat exchange coefficient of each boundary region of the hot rolling working rolls can be calculated; and then a temperature analysis model and a stress-strain analysis model of the hot rolling working roll can be constructed by a finite element analysis method. And the analysis result of the model can be used for obtaining the temperature gradient respectively result and circumferential stress distribution result of the surface of the hot rolling working roll within the range of 0-5 mm.
For test rolls on a disk-type twin-roll thermal wear tester, the type zones of boundary conditions can be divided as shown in fig. 4:
fig. 4 shows in particular the relative positions of the loading roller 6, the test roller 7, the test water deflector 8, and the test coolant nozzle 9. In this embodiment, it is considered that the air cooling zone has little effect on the heat transfer performance of the system; in order to improve the cooling effect, no air cooling area was provided in the equivalent test. Therefore, according to the specific layout of the loading roller 6, the test water baffle 8, and the test coolant nozzle 9, the circumferential direction of the test roller 7 can be divided into the following regions: according to the anticlockwise direction, the interval I-II is an occlusion zone, the intervals II-III and V-I are radiation zones, the interval III-IV is a jet cooling zone, and the interval IV-V is a water baffle cooling zone.
In the embodiment, in order to simulate the real hot rolling process, aiming at a disc type twin-roll hot wear testing machine and a testing roll, equipment and process parameters are set up by the following method;
1. the stress on the test roll in the embodiment can be equivalent to the test force of the radial load of the high-temperature rolling piece on the test roll in the hot rolling process; define the force as equivalent test force p t The calculation formula is as follows:
In the above formula, p is the hot rolling force, and B is the width of the workpiece; l is the contact arc length of the test roll and the workpiece, ρ is the comprehensive curvature radius of the test piece and the loading roll, b is the roll width of the test roll, μ 1 Sum mu 2 Poisson ratio of test piece and loading roller at test temperature, E 1 And E is 2 The modulus of elasticity of the test roller and the loading roller at the test temperature, respectively.
2. In the embodiment, the equivalent test rotating speed n is defined by the heating process of the high-temperature rolled piece on the working roll in the nip area in the hot rolling process t The calculation formula is obtained as follows:
in the above formula, n is the rotating speed of the test roller, l is the contact arc length of the test roller and the workpiece, l t For the contact arc length of the test roller and the loading roller, h c The average heat exchange coefficient of the biting area of the hot rolling working roll and the workpiece is h t The average heat exchange coefficient of the nip area of the test roll and the loading roll.
3. In this embodiment, considering that there is sufficient time between the work and the loading roller to complete heat conduction, the loading temperature of the loading roller is set to be the same as the temperature of the rolled piece in the actual hot rolling process, that is:
T t ＝T s
in the above, T t Loading temperature for loading roller in performance test, T s Is the temperature of the rolled piece in the actual hot rolling.
4. In this embodiment, in order to be consistent with the actual hot rolling process, the coolant injection pressure is set to be the same as that of the actual hot rolling mill, that is
P t ＝P ht
In the above, P t For the coolant injection pressure, P in the performance test ht The pressure of the cooling liquid injection in the real hot rolling mill is obtained.
Calculated from the company to obtain equivalent test force p t Equivalent test speed n t Loading temperature T of loading roller t And a coolant injection pressure P t And carrying the parameters into different types of heat exchange boundary conditions, calculating and obtaining the heat exchange coefficient of each boundary region of the test roller, and constructing the problem gradient and the circumferential stress-strain distribution of the surface of the test roller within the range of 0-5 mm.
Specifically, in the present embodiment, in the true hot-rolled work roll and test roll, the distribution diagram of the circumferential stress as a function of the depth from the surface of the work roll is shown in fig. 5; in a real hot rolled work roll and test roll, the profile of temperature as a function of depth from the work roll surface is shown in FIG. 5.
Through calculation, the extreme errors of the temperature gradient and the circumferential strain of the real hot rolling working roll and the test roll for performance test are found to be within 5%. Therefore, the full true simulation in the real rolling process is realized in the simulated rolling process in the embodiment, and the hot rolling process under the real working condition can be accurately simulated in the simulated rolling process on the disc type twin-roll hot wear testing machine. At this time, the calculated equivalent test force p is extracted t Equivalent test speed n t Loading temperature T of loading roller t And a coolant injection pressure P t The method comprises the steps of carrying out a first treatment on the surface of the As test parameters for final wear and thermal fatigue comprehensive performance evaluation.
3. Comprehensive performance evaluation test
In the embodiment, the loading temperature of a loading roller is set to be the temperature of a rolled piece in a required simulated hot rolling working condition; setting the test force of the test roller as the calculated equivalent test force; the rotating speed of the test roller is set to be the calculated equivalent rotating speed; the cooling fluid pressure is the same as that set in the actual hot rolling process. And the performance test is operated until the condition that the surface of the test roller is detected to have cracks with preset length to stop. The whole test process uses pulse eddy current nondestructive testing equipment to monitor the surface crack condition in real time on line. And quantitatively evaluating the comprehensive performances of the abrasion and the thermal fatigue of the test roller according to the state of the occurrence of the crack on the surface of the test roller and the occurrence time of the crack, so as to obtain the performance evaluation result of the test roller.
Example 2
The present embodiment provides a remanufactured hot-rolled work roll comprehensive performance evaluation system which adopts the remanufactured hot-rolled work roll comprehensive performance evaluation method in embodiment 1 to simulate the real working conditions of the hot-rolled work rolls and accurately evaluate the comprehensive performance of the test rolls generated by the remanufacturing process.
The comprehensive performance evaluation system of the hot rolling working roll comprises: the system comprises a model generation module, an error comparison module, a test parameter acquisition module and a performance test control module.
The model generation module is used for constructing a temperature analysis model and a stress-strain model of the test roller according to test parameters for simulating the rolling process. The model generation module comprises a type region classification unit, an initial value updating unit and a data analysis unit. The type area classification unit is used for dividing boundary conditions of the test roller into five types of areas along the circumferential direction according to analysis results of the test roller under actual working conditions, wherein the five types of areas are respectively an occlusion area, a radiation area, a water baffle cooling area, a jet cooling area and an air cooling area; and constructing heat exchange boundary conditions of each type of region based on the judgment result of the heat transfer type of each different type of region on the test roller. The initial value updating module is used for initializing the initial value n of the test rotating speed in the simulated rolling process before the test starts or when the extreme value error between the result of each simulated rolling and the real working condition does not meet the requirement t0 And an initial value P of the coolant injection pressure t0 And (5) automatically updating. The data analysis unit is used for performing simulated rolling after the initial value updating module completes the value updating, obtaining the values of all test parameters in the heat exchange boundary conditions of the simulated rolling process, and calculating the equivalent test in the current simulated rolling process Force of test p t And equivalent test speed n t At the same time, the loading temperature T of the loading roller is obtained t And a coolant injection pressure P t The method comprises the steps of carrying out a first treatment on the surface of the And then equivalent test force p t Equivalent test speed n t Loading temperature T of loading roller t And a coolant injection pressure P t Substituting the four values into a heat exchange boundary condition, and calculating heat exchange coefficients of different types of areas in the test roller; and then a temperature analysis model and a stress-strain analysis model of the test roller under the current working condition are built.
The error comparison module is used for acquiring the analysis result of the temperature gradient and circumferential stress distribution of the test roller in the simulation processing process, which is obtained in the model generation module; the analysis results of the temperature gradient and circumferential stress distribution of the real hot rolling working roll under the same working condition are obtained; and then the extreme value errors of the two are calculated.
The test parameter acquisition module is used for acquiring an equivalent test force P under the current working condition when the extreme value error calculation result output by the error comparison module is less than or equal to 5 percent t Equivalent test speed n t Loading temperature T of loading roller t And a coolant injection pressure P t And four values were used as test parameters in the comprehensive performance evaluation test.
The performance test control module is used for controlling the abrasion and thermal fatigue comprehensive performance test process of the test roller by taking the numerical value output by the test parameter acquisition module as the numerical value of the test parameter in the comprehensive performance evaluation test; and further obtaining the comprehensive performance evaluation result of the test roller, wherein the result is the comprehensive performance evaluation result of the working roller under the real working condition.
The invention provides a remanufacturing hot rolling working roll comprehensive performance evaluation system, which is an automatic control system for implementing the comprehensive performance evaluation method. The system based on the automatic programming can be installed in the existing disc type twin-roll thermal wear testing machine to evaluate and test the performance of each type of working roll. And the automatic test is realized, and the evaluation conclusion is rapidly obtained. And the efficiency and the accuracy of the comprehensive performance evaluation of the hot rolling working rolls are improved.
Example 3
The embodiment provides a method for evaluating comprehensive performance of a remanufactured hot-rolled working roll. This method is similar to the procedure provided in example 1. The difference is that: in this example, the method was used for evaluating the wear and thermal fatigue performance of a new roll of a hot rolling work roll.
In the actual production process, the manufacturing processes adopted by the new roll and the remanufactured roll of the hot-rolled working roll are different, for example, the new roll is mainly manufactured by adopting a centrifugal casting method and the like, and the remanufactured roll is mainly obtained by repairing the surface of the hot-rolled working roll after failure and retirement through a laser cladding or plasma cladding technology.
As the performance consistency of the hot rolling working roll products produced completely new is better, the surface hardness and the roughness can meet the requirements. Therefore, the comprehensive performance evaluation method provided in this embodiment only needs to fine-tune the steps of the method in embodiment 1, and omits or adjusts the pretreatment process step in S1.
This example can explain: the technical scheme provided by the embodiment not only can carry out comprehensive performance evaluation on the repaired hot-rolled working roll generated by the remanufacturing process, but also can carry out comprehensive performance evaluation on the hot-rolled working roll which is produced completely new, and the scheme has wide adaptability and high practicability.
Example 4
This example provides a method for evaluating the overall performance of a cold roll, which is similar to that of example 3, with the difference that: the method in the embodiment is applied to evaluate the comprehensive performance of the wear and the thermal fatigue of the cold rolling working roll.
In the cold rolling process and the hot rolling process, heat sources which cause the temperature rise of the working rolls in the occlusion area are different, the heat sources in the hot rolling process mainly are the self temperature of a high-temperature rolled piece, and the heat sources in the cold rolling process mainly are the heat generated by plastic deformation and friction of the rolled piece. Therefore, the comprehensive performance evaluation method provided by the technical scheme in the embodiment needs to change the calculation method of the loading temperature of the loading roller in the test parameters. In the present embodiment, the loading roller loading temperature T t The calculation formula of (2) is as follows:
T t ＝T s +ΔT def +ΔT f
in the above, T s For the actual initial temperature of the cold rolled piece, deltaT def For temperature rise, deltaT, caused by plastic deformation of the rolled piece f Is the temperature rise caused by the friction between the rolled piece and the roller.
Through the improvement of the calculation method, the evaluation method of the technical scheme can be suitable for evaluating the comprehensive performance of the abrasion and the thermal fatigue of the new cold rolling working roll. The adaptability of the method provided in the embodiments of the present invention is further improved.
In summary, compared with the existing test method, the comprehensive performance evaluation method and system in embodiments 1-4 of the present invention have the following advantages:
in the test method provided by the invention, the influences of three loads of thermal stress caused by thermal expansion in the hot rolling process, residual stress generated in the manufacturing process and mechanical stress generated by strip extrusion in the rolling process on the damage of the working roll are simultaneously considered, and the 'full true simulation' of the actual working condition of the hot rolling working roll is realized through the equivalent calculation and analysis of test parameters and the improvement and application of a disc type abrasion tester, so that the obtained performance test data is more accurate.
The method and the system provided by the invention combine numerical calculation and equivalent tests, ensure the accuracy of conclusion, and can complete the test process only by an improved disc type abrasion tester without testing on the rolling machinery which is actually operated. So that the test period and the test cost can be effectively reduced on the basis of ensuring the accuracy of the comprehensive performance evaluation of wear and thermal fatigue,
The method and the system provided by the invention can evaluate the comprehensive performances of wear and thermal fatigue of the hot rolling working rolls in different times under various working conditions; and full-period basic test data are provided for the remanufacturing process development of the hot rolling working roll, the improvement of the wear resistance and thermal fatigue resistance comprehensive performance and the life prediction.
The method and the system provided by the invention can be used for simulating the real working condition of the hot rolling remanufacturing working roll and evaluating the comprehensive performance; and the wear and thermal fatigue comprehensive performance evaluation method is also suitable for the new roll wear and thermal fatigue comprehensive performance evaluation of the hot/cold rolling working roll. And the technical effect of acquiring the damage evolution data of the test roller in the whole test process on line can be realized. Has higher practical value.
The technical features of the above-described embodiments may be arbitrarily combined, and all possible combinations of the technical features in the above-described embodiments are not described for brevity of description, however, as long as there is no contradiction between the combinations of the technical features, they should be considered as the scope of the description.
The above examples merely represent a few embodiments of the present invention, which are described in more detail and are not to be construed as limiting the scope of the invention. It should be noted that it will be apparent to those skilled in the art that several variations and modifications can be made without departing from the spirit of the invention, which are all within the scope of the invention. Accordingly, the scope of the invention should be assessed as that of the appended claims.
Claims (10)
1. A remanufactured hot rolling working roll comprehensive performance evaluation method is characterized by comprising the following steps of: the comprehensive performance evaluation method is used for evaluating the performance of the hot rolling working roll generated by the remanufacturing process; the method comprises the following steps:
s1: preprocessing the test roller to meet the simulation condition that the test roller can achieve the real working condition of the hot rolling working roller; the preprocessing process comprises a heat treatment process and a surface processing process;
s2: the test roll is used for carrying out simulated rolling on a workpiece, so as to obtain an equivalent test force p in the simulated rolling process t Equivalent test speed n t Loading temperature T of loading roller t And a coolant injection pressure P t The method comprises the steps of carrying out a first treatment on the surface of the The process is specifically as follows:
s21: according to the analysis result of the test roller under the actual working condition, dividing the boundary condition of the test roller into five types of areas along the circumferential direction, wherein the five types of areas are respectively an engagement area, a radiation area, a water baffle cooling area, a jet cooling area and an air cooling area;
s22: based on the judgment result of the heat transfer type of each different type region on the test roller, constructing the heat exchange boundary condition of each type region;
s23: setting an initial value n of a test rotating speed t0 And an initial value P of the coolant injection pressure t0 Performing simulated rolling to obtain numerical values of each test parameter in the heat exchange boundary condition in the simulated rolling process,
and calculating the equivalent test force p in the current simulated rolling process t And equivalent test speed n t At the same time, the loading temperature T of the loading roller is obtained t And a coolant injection pressure P t ；
S24: calculating heat exchange coefficients of different types of areas in the test roller, and setting the equivalent test force p t Equivalent test speed n t Loading temperature T of loading roller t And a coolant injection pressure P t Substituting the heat exchange boundary conditions; further constructing a temperature analysis model and a stress-strain analysis model of the test roller under the current working condition;
s25: analyzing the temperature gradient and circumferential stress distribution of the surface of the test roller within the range of 0-5mm according to the constructed temperature analysis model and the stress-strain analysis model;
s26: obtaining analysis results of temperature gradient and circumferential stress distribution of a real hot rolling working roll under the same working condition; comparing the temperature gradient of the test roll with the analysis result of the circumferential stress distribution of the real hot rolling working roll, and calculating the extreme value error of the test roll and the real hot rolling working roll; and making a judgment according to the result of the extreme value error:
(1) When the extreme value error is less than or equal to 5%, the test roller is considered to reach the simulation requirement of the real working condition; at this time, an equivalent test force p obtained in the simulated rolling process under the current working condition is obtained t Equivalent test speed n t Loading temperature T of loading roller t And a coolant injection pressure P t Specific values of (2);
(2) When the extreme value error is more than 5%, the test roller is considered to not reach the simulation requirement of the real working condition;
at this time, the procedure returns toS23, performing S23; adjusting the initial value n of the test rotating speed t0 And an initial value P of the coolant injection pressure t0 Re-executing the simulated rolling process; until the simulation requirement of the real working condition is met;
s3: equivalent test force p obtained in the previous step t Equivalent test speed n t Loading temperature T of loading roller t And a coolant injection pressure P t And (3) performing abrasion and thermal fatigue comprehensive performance test on the test roller as test parameters of the comprehensive performance evaluation test to obtain a comprehensive performance evaluation result of the test roller, wherein the result is a comprehensive performance evaluation result of the working roller under a real working condition.
2. The remanufactured hot rolled work roll comprehensive performance evaluation method according to claim 1, wherein: in the step S1, the heat treatment process comprises oil quenching treatment and tempering treatment twice according to time sequence, and after the heat treatment process is finished, the surface hardness of the test roller is not less than 60HRC at room temperature; after the surface processing technology is finished, the surface roughness Ra of the test roll is between 0.8 and 1.6 mu m.
3. The remanufactured hot rolled work roll comprehensive performance evaluation method according to claim 1, wherein: the simulated rolling process of the step S2 and the abrasion and thermal fatigue comprehensive performance test process of the step S3 are completed in a disc type twin-roll thermal abrasion tester.
4. The remanufactured hot rolled work roll comprehensive performance evaluation method according to claim 3, wherein: in the simulated rolling process of the step S2, the friction coefficient between the workpiece and the test piece reaches the minimum value on the basis of ensuring that the biting condition is met by adjusting the concentration of the cooling liquid; the minimum value is defined as a test friction coefficient, which is in the range of 0.15-0.4.
5. The remanufactured hot rolled work roll comprehensive performance evaluation method according to claim 1, wherein: in step S23, the equivalentTest force p t The calculation formula of (2) is as follows:
in the above formula, p is the hot rolling force, and B is the width of the workpiece; l is the contact arc length of the test roll and the workpiece, ρ is the comprehensive curvature radius of the test piece and the loading roll, b is the roll width of the test roll, μ 1 Sum mu 2 Poisson ratio of test piece and loading roller at test temperature, E 1 And E is 2 The modulus of elasticity of the test roller and the loading roller at the test temperature, respectively.
6. The remanufactured hot rolled work roll comprehensive performance evaluation method according to claim 1, wherein: the equivalent test rotation speed n t The calculation formula of (2) is as follows:
in the above formula, n is the rotating speed of the test roller, l is the contact arc length of the test roller and the workpiece, l t For the contact arc length of the test roller and the loading roller, h c The average heat exchange coefficient of the biting area of the hot rolling working roll and the workpiece is h t The average heat exchange coefficient of the nip area of the test roll and the loading roll.
7. The remanufactured hot rolled work roll comprehensive performance evaluation method according to claim 1, wherein: in the abrasion and thermal fatigue comprehensive performance test process in the step S3, the crack condition of the surface of the test roller is monitored online in real time through nondestructive testing equipment until the abrasion and thermal fatigue comprehensive performance test is stopped when the crack with the preset length is detected on the surface of the test roller.
8. The method for evaluating the overall performance of a remanufactured hot rolled work roll according to claim 7, wherein: the nondestructive testing equipment monitors surface cracks of the test roller through a non-contact scanning method; the scanning frequency of the nondestructive testing equipment is larger than the rotating frequency of the test roller, and the detection precision of the nondestructive testing equipment is smaller than 0.5mm.
9. A remanufactured hot rolling working roll comprehensive performance evaluation system is characterized in that: the comprehensive performance evaluation system of the hot rolling working roll adopts the comprehensive performance evaluation method of the remanufactured hot rolling working roll according to any one of claims 1-8 to simulate the real working condition of the hot rolling working roll and accurately evaluate the comprehensive performance of the test roll produced by the remanufacturing process; the hot rolling working roll comprehensive performance evaluation system comprises:
the model generation module is used for constructing a temperature analysis model and a stress-strain model of the test roller according to the test parameters of the simulated rolling process; the model generation module comprises a type region classification unit, an initial value updating unit and a data analysis unit; the type region classification unit is used for dividing boundary conditions of the test roller into five types of regions, namely an occlusion region, a radiation region, a water baffle cooling region, a jet cooling region and an air cooling region, along the circumferential direction according to analysis results of the test roller under actual working conditions; based on the judgment result of the heat transfer type of each different type region on the test roller, constructing the heat exchange boundary condition of each type region; the initial value updating module is used for updating the initial value n of the test rotating speed before the test starts or when the extreme value error between the result of each simulated rolling and the real working condition does not meet the requirement t0 And an initial value P of the coolant injection pressure t0 Automatically updating; the data analysis unit is used for performing simulated rolling after the initial value updating module completes numerical value updating, obtaining numerical values of all test parameters in the heat exchange boundary conditions in the simulated rolling process, and calculating an equivalent test force p in the current simulated rolling process t And equivalent test speed n t At the same time, the loading temperature T of the loading roller is obtained t And a coolant injection pressure P t The method comprises the steps of carrying out a first treatment on the surface of the And then the equivalent test force p t Equivalent test speed n t Loading temperature T of loading roller t And a coolant injection pressure P t Substituting the four values into the heat exchange boundary conditions, and calculating heat exchange coefficients of different types of areas in the test roller; further constructing a temperature analysis model and a stress-strain analysis model of the test roller under the current working condition;
the error comparison module is used for acquiring the temperature gradient of the test roller obtained in the model generation module in the simulation processing process and the analysis result of circumferential stress distribution; the analysis results of the temperature gradient and circumferential stress distribution of the real hot rolling working roll under the same working condition are obtained; further calculating the extreme value error of the two;
the test parameter acquisition module is used for acquiring the equivalent test force p under the current working condition when the extreme value error calculation result output by the error comparison module is less than or equal to 5 percent t Equivalent test speed n t Loading temperature T of loading roller t And a coolant injection pressure P t And taking the four values as test parameters in the comprehensive performance evaluation test;
the performance test control module is used for controlling the process of the abrasion and thermal fatigue comprehensive performance test of the test roller by taking the numerical value output by the test parameter acquisition module as the numerical value of the test parameter in the comprehensive performance evaluation test; and further obtaining the comprehensive performance evaluation result of the test roller, wherein the result is the comprehensive performance evaluation result of the working roller under the real working condition.
10. The remanufactured hot rolled work roll comprehensive performance evaluation system according to claim 9, wherein: the remanufactured hot rolling working roll comprehensive performance evaluation system is applied to a disc type twin-roll thermal wear testing machine; in the wear and thermal fatigue comprehensive performance test, the test roller is used for simulating three loads, namely thermal stress caused by expansion born by a working roller in actual hot rolling, residual stress generated in the manufacturing process and mechanical stress generated by strip extrusion in the rolling process.
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| JPH07151717A (en) * | 1993-11-29 | 1995-06-16 | Nippon Steel Corp | Method for learning and computing profile of reduction roll |
| JP2010101752A (en) * | 2008-10-23 | 2010-05-06 | Jfe Steel Corp | Method for evaluating roll for hot rolling |
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