CN115121771B

CN115121771B - Intelligent ultrasonic continuous casting method and measuring and controlling device for metal section

Info

Publication number: CN115121771B
Application number: CN202210889198.8A
Authority: CN
Inventors: 王建元; 翟薇; 王金钊; 魏炳波
Original assignee: Northwestern Polytechnical University
Current assignee: Northwestern Polytechnical University
Priority date: 2022-07-27
Filing date: 2022-07-27
Publication date: 2023-06-09
Anticipated expiration: 2042-07-27
Also published as: CN115121771A

Abstract

The invention relates to an intelligent ultrasonic continuous casting method of metal section and a measurement and control device, wherein the method comprises the steps of obtaining core energy field parameters, shape control parameters, process parameters, working condition environment parameters, a first quantitative relation, an alloy cavitation threshold and Shi Zhenshi test data of a metal material, a target section performance control index and a solidification condition; optimizing the metal material according to the target profile performance control index and the core energy field parameter of the solidification condition to obtain a metal material parameter; optimizing the continuous casting mold according to the shape control parameter, the technological parameter and the working condition environment parameter; optimizing continuous casting process parameters according to the first quantitative relation and the alloy cavitation threshold; optimizing an ultrasonic vibration applying system according to the Shi Zhenshi test data, and determining ultrasonic continuous casting control parameters according to all optimization results; and carrying out ultrasonic continuous casting according to the ultrasonic continuous casting control parameters to obtain the metal section. The invention can realize the balance of quality, efficiency and cost.

Description

Intelligent ultrasonic continuous casting method and measuring and controlling device for metal section

Technical Field

The invention relates to the field of advanced material manufacturing, in particular to an intelligent ultrasonic continuous casting method and a measurement and control device for metal profiles.

Background

With the increasing requirements of important technical fields such as national defense and military industry, aerospace, bridge ships, energy traffic and the like on the performance, precision, cost and period of steel materials, the requirements of the country on energy efficiency and ecological environment are more stringent, and the common problem in the continuous casting field, which is the steel casting forming technology with the largest occupation ratio, is to be solved.

The continuous casting technology is a main means of industrial production of metal bars, plates, pipes or profiles, and is characterized in that liquid molten steel in a tundish flows into a built-in die of a water-cooled crystallizer sealed by a dummy bar under the action of gravity, a thin and firm metal shell is rapidly formed along a cold die wall, and then the thin shell is thickened along with the external pulling of the dummy bar and gradually solidified into a profile blank.

However, the continuous casting process is a quasi-steady-state metallurgical process involving high-temperature melt charging flow, liquid-solid unbalanced phase transition, semi-solid multiphase turbulence, solid phase transition of a solidified profile and accompanying non-uniform momentum heat mass transmission and complex interface behaviors, wherein the physical field coupling effects of a temperature field, a flow field, a phase field, a stress field and the like are strong, the heat mass momentum transmission process and the interface behaviors of the metal material liquid-solid unbalanced transition are extremely complex, the significant changes and differences of solute distribution characteristics, nucleation phase formation mechanisms, tissue morphology evolution, profile forming quality and toughness performance are caused, and the intrinsic causes of defects such as gas-coiling slag inclusion, cold insulation heat cracking, loosening shrinkage cavity, segregation deformation and the like are also caused.

Therefore, the existing continuous casting technology still has the technical problems that the surface roughness, the composition tissue segregation, the porosity shrinkage, the crack sensitivity, the uneven performance and the like cannot meet the actual demands of advanced material development and high-end manufacturing industry, and in addition, no complete and feasible general low-cost solution exists in the aspects of accurate control of the chemical composition, nucleation particle and microstructure distribution and the overall toughness performance of the continuous casting blank, so that the optimization of transformation upgrading in the continuous casting industry and the design, preparation and large-scale production application of advanced materials are seriously hindered.

In view of the fact that the existing continuous casting technology still cannot achieve the balance of quality, efficiency and cost and the breakthrough of generality, it is urgent to develop a novel high-quality, high-efficiency and low-cost universal process controllable continuous casting technology.

Disclosure of Invention

The invention aims to provide an intelligent ultrasonic continuous casting method and a measurement and control device for metal profiles, so as to realize the balance of quality, efficiency and cost.

In order to achieve the above object, the present invention provides the following solutions:

an intelligent ultrasonic continuous casting method for metal profiles, comprising the following steps:

acquiring a metal material, a target profile performance control index, a core energy field parameter of a solidification condition, a shape control parameter, a process parameter, a working condition environment parameter, a first quantitative relation, an alloy cavitation threshold value and Shi Zhenshi test data;

optimizing the metal material according to the target profile performance control index and the core energy field parameter of the solidification condition to obtain a metal material parameter;

optimizing the continuous casting mold according to the shape control parameter, the technological parameter and the working condition environment parameter to obtain a continuous casting mold parameter;

optimizing continuous casting process parameters according to the first quantitative relation and the alloy cavitation threshold value to obtain an ultrasonic continuous casting process quantitative relation;

Optimizing an ultrasonic vibration applying system according to the Shi Zhenshi test data to obtain vibration applying parameters;

determining ultrasonic continuous casting control parameters according to the metal material parameters, the continuous casting mold parameters, the continuous casting process quantitative relation and the vibration applying parameters;

and carrying out ultrasonic continuous casting according to the ultrasonic continuous casting control parameters to obtain the metal section.

An intelligent ultrasonic continuous casting measurement and control device for metal profiles, comprising:

the acquisition module is used for acquiring core energy field parameters, shape control parameters, process parameters, working condition environment parameters, a first quantitative relation, an alloy cavitation threshold and Shi Zhenshi test data of the metal material, the target profile performance control index and the solidification condition;

the metal material optimizing module is used for optimizing the metal material according to the target profile performance control index and the core energy field parameter of the solidification condition to obtain metal material parameters;

the continuous casting mold optimizing module is used for optimizing the continuous casting mold according to the shape control parameter, the technological parameter and the working condition environment parameter to obtain continuous casting mold parameters;

the continuous casting process parameter optimization module is used for carrying out continuous casting process parameter optimization according to the first quantitative relation and the alloy cavitation threshold value to obtain a continuous casting process quantitative relation;

The ultrasonic vibration system optimizing module is used for optimizing the ultrasonic vibration system according to the Shi Zhenshi test data to obtain vibration parameters;

the ultrasonic continuous casting control parameter determining module is used for determining ultrasonic continuous casting control parameters according to the metal material parameters, the continuous casting mold parameters, the continuous casting process quantization relation and the vibration applying parameters;

and the ultrasonic continuous casting module is used for carrying out ultrasonic continuous casting according to the ultrasonic continuous casting control parameters to obtain the metal section.

According to the specific embodiment provided by the invention, the invention discloses the following technical effects:

the method comprises the steps of obtaining a core energy field parameter, a shape control parameter, a process parameter, a working condition environment parameter, a first quantitative relation, an alloy cavitation threshold value and Shi Zhenshi test data of a metal material, a target profile performance control index and a solidification condition; optimizing the metal material according to the target profile performance control index and the core energy field parameter of the solidification condition to obtain a metal material parameter; optimizing the continuous casting mold according to the shape control parameter, the technological parameter and the working condition environment parameter to obtain a continuous casting mold parameter; optimizing continuous casting process parameters according to the first quantitative relation and the alloy cavitation threshold value to obtain a continuous casting process quantitative relation; optimizing an ultrasonic vibration applying system according to the Shi Zhenshi test data to obtain vibration applying parameters; determining ultrasonic continuous casting control parameters according to the metal material parameters, the continuous casting mold parameters, the continuous casting process quantitative relation and the vibration applying parameters; and carrying out ultrasonic continuous casting according to the ultrasonic continuous casting control parameters to obtain the metal section, thereby realizing the balance of quality, efficiency and cost.

Drawings

In order to more clearly illustrate the embodiments of the present invention or the technical solutions of the prior art, the drawings that are needed in the embodiments will be briefly described below, it being obvious that the drawings in the following description are only some embodiments of the present invention, and that other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.

FIG. 1 is a flow chart of an intelligent ultrasonic continuous casting method for metal profiles;

FIG. 2 is a schematic diagram of an intelligent ultrasonic continuous casting method of a metal section;

FIG. 3 is a schematic diagram of an intelligent ultrasonic continuous casting measurement and control device for metal profiles;

FIG. 4 is a schematic diagram of a quantitative modeling flow of an intelligent ultrasonic continuous casting process system for metal profiles;

FIG. 5 is a schematic diagram of a process control logic framework for intelligent ultrasonic continuous casting of metal profiles;

fig. 6 is a graph of results of acoustic-flow-solid coupling calculation analysis of liquid phase cavity data in the process of ultrasonic continuous casting of a plate.

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.

In order that the above-recited objects, features and advantages of the present invention will become more readily apparent, a more particular description of the invention will be rendered by reference to the appended drawings and appended detailed description.

As shown in fig. 1, the intelligent ultrasonic continuous casting method for metal profiles provided by the invention comprises the following steps:

step 101: and acquiring core energy field parameters, shape control parameters, process parameters, working condition environment parameters, a first quantitative relation, an alloy cavitation threshold and Shi Zhenshi test data of the metal material, the target profile performance control index and the solidification condition.

Step 102: and optimizing the metal material according to the target profile performance control index and the core energy field parameter of the solidification condition to obtain metal material parameters. The method comprises the steps of optimizing the metal material according to the target profile performance control index and the core energy field parameter of the solidification condition to obtain metal material parameters, and specifically comprises the following steps: and optimizing the metal material by taking the target profile performance control index as an objective function and utilizing a density functional theory according to the core energy field parameters of the solidification condition to obtain metal material parameters.

The metal material parameters comprise material components, abnormal conditions, a quantitative relation model between a microstructure and performance, and are used for guiding materials and continuous casting process design; master alloy material composition for producing target profile.

Step 103: and optimizing the continuous casting mold according to the shape control parameter, the technological parameter and the working condition environment parameter to obtain the continuous casting mold parameter. Wherein, optimizing the continuous casting mold according to the shape control parameter, the technological parameter and the working condition environment parameter to obtain continuous casting mold parameters, specifically comprising:

and carrying out three-dimensional modeling according to the shape control parameters, the process parameters and the working condition environment parameters to obtain a three-dimensional model.

And carrying out steady-state solving by utilizing a three-dimensional fluid heat transfer equation, a liquid-solid phase change state equation and a thermal expansion equation according to the three-dimensional model to obtain a change rule from the axial initial crusting position to the diameter shrinkage rate of the solid phase type shell at the outlet of the crystallizer.

And optimizing the continuous casting mold according to the change rule and the technological parameters to obtain continuous casting mold parameters.

The parameters of the continuous casting mold comprise the optimal hole shape and the optimal circumferential taper curved surface of the ultrasonic continuous casting profile mold, and the parameters are used for designing the continuous casting mold; the section shape nc_SS of the continuous casting section at the outlet of the crystallizer is used for evaluating the forming precision of the continuous casting section; the solid-liquid two-phase three-dimensional model SLM is used for subsequent modal harmonious response analysis.

Step 104: and optimizing continuous casting process parameters according to the first quantitative relation and the alloy cavitation threshold value to obtain a continuous casting process quantitative relation. And optimizing continuous casting process parameters according to the first quantitative relation and the alloy cavitation threshold value to obtain a continuous casting process quantitative relation, wherein the continuous casting process quantitative relation specifically comprises the following steps:

performing coupling calculation according to the first quantization relation and the alloy cavitation threshold value, and determining ideal vibration mode information; the first quantitative relationship is a quantitative relationship among a matrix grain average size, a strengthening phase dispersion, ultrasonic cavitation intensity, a liquid phase cavitation rate and cavitation uniformity.

Determining a second quantization relation by utilizing a deep learning quantization modeling method according to the ideal vibration mode information; the second quantitative relation is the quantitative relation among the contact stress between the surface of the solid-phase shell and the inner wall surface of the die, the actual contact area, the vibration applying position of the wall surface of the solid-phase shell, the vibration amplitude of the outer wall surface, the continuous casting blank drawing speed and the inlet temperature of the crystallizer.

And determining the quantitative relation of the continuous casting process according to the second quantitative relation. The quantitative relation of the continuous casting process comprises a quantitative relation F_ap4fpa, which is used for determining the input parameter range of the quantitative relation F_ap4fpa and guiding the design of ultrasonic continuous casting equipment and the model selection of parts; a quantitative relationship f_c4 tfplatv for determining horn replacement cycles; friction resistance Fr for determining traction.

Step 105: and optimizing the ultrasonic vibration applying system according to the Shi Zhenshi test data to obtain vibration applying parameters. Wherein the vibration parameters include a quantization relationship F_med4fpax for process control; a deployed online neural network; and (5) an ultrasonic continuous casting control strategy.

Step 106: and determining ultrasonic continuous casting control parameters according to the metal material parameters, the continuous casting mold parameters, the continuous casting process quantitative relation and the vibration applying parameters.

Step 107: and carrying out ultrasonic continuous casting according to the ultrasonic continuous casting control parameters to obtain the metal section.

The ultrasonic continuous casting method provided by the method is based on an ultrasonic solidification process regulation technology, and comprises the following steps:

firstly, designing and optimizing an advanced metal material, constructing a metal material to enable a service performance to be accurate prediction model based on a multi-state multi-physical-field trans-scale interaction mechanism of high-energy ultrasound and the metal material, optimizing material components, physicochemical properties, microstructures, interface structures and mechanical properties, and developing the advanced metal material with wide application scenes; according to the service scene and the application requirement of the metal section, the metal material composition is designed and optimized and used as the master alloy for producing the metal section.

The advanced metal material, namely ultrasonic continuous casting section master alloy, is developed for new metal materials and updated for traditional materials, and specifically comprises novel metal structural materials such as intermetallic compounds, amorphous/high-entropy alloys, high-temperature alloys, metal matrix composite materials and the like, and advanced steel materials such as high-strength steel, bearing steel, tool and die steel, wear-resistant corrosion-resistant steel and the like. The material composition design optimization refers to brand new composition design of novel alloy, element replacement or content and composition optimization of traditional metal materials. The metal material polymorphism refers to metal solid-liquid-gas tristate of metal gas, high-temperature molten metal liquid, metal solid generated by liquid-solid phase change and the like existing in cavitation bubbles caused by super-strong acoustic cavitation. The multi-physical field refers to a high-energy ultrasonic excitation ultrasonic field, a flow field, a cavitation induced micro-region ultra-high temperature field, an ultra-high pressure field, a continuous casting temperature field, a speed field, an electromagnetic field caused by magnetic control turbulence, a liquid-solid phase change induced solute field, a phase field and a coupling field thereof. The scale refers to space scales such as quantum scale, atomic scale, micro scale, macro scale and the like and the corresponding scale of from 10 ^-15 Time scale from seconds to years. The ultrasonic solidification process refers to the influence process of the phenomena of interface wetting, uniform or heterogeneous nucleation, free migration of crystal nucleus, grain growth, dendrite detachment, dendrite breakage and the like in the alloy solidification process by modulating high-energy ultrasonic. The modulated high-energy ultrasound has the functions of driving dispersion and alloyChange, phase change, stress release, etc.

The advanced metal material design and optimization comprises the following steps:

(1) According to the actual use performance requirements and the service environment of the profile, determining the performance control indexes such as the strength (yield strength YS and tensile strength TS), plasticity (elongation ET and area reduction AR), toughness (brittle transition temperature TC and fracture toughness FT) and the like of the target profile; (1) The performance parameters of the target profile are the targets of the composition design of the master alloy material.

(2) The core energy field parameters of the ultrasonic continuous casting process under the supernormal solidification condition and the boundaries thereof, namely a temperature field T epsilon [ min_T, max_T ], a pressure field P epsilon [ min_P, max_P ], a magnetic field M epsilon [ min_M, max_M ], an electric field E epsilon [ min_E, max_E ] and the like are determined by combining experimental actual measurement and modeling calculation; (2) The core energy field parameters of ultrasonic solidification conditions and boundaries thereof determine the ranges of pure component thermodynamic data, a multi-element alloy system phase diagram and a quantitative relation model.

(3) The contribution of the supernormal solidification condition to the free energy of the condensed phase Gibbs and the influence on the stability of the solid phase are calculated and determined by means of the first sexual principle based on the Density Functional Theory (DFT), and the lattice stability parameters, namely pure component thermodynamic data, including interfacial energy, lattice constant, elastic constant and other physical properties of the single-element, binary and ternary stable phases and the metastable phase, entropy, enthalpy, heat capacity and other thermodynamic properties, self-diffusion coefficient, inter-diffusion coefficient, impurity diffusion coefficient and other kinetic properties are obtained.

(4) According to lattice stability parameters, phase balance high-flux calculation is carried out by means of a calculated phase diagram CALPHAD method in combination with experimental data, and an ultra-normal multi-element alloy system phase diagram for ultrasonic continuous casting is obtained, wherein the phase diagram comprises phase compositions, physical properties, thermodynamic properties and kinetic properties of each phase.

(5) According to the properties of each constituent phase of a multi-element alloy system, high-throughput simulation of a microstructure evolution process is carried out by means of a multi-element phase field model in combination with experimental data, and the intrinsic mechanisms of behaviors such as phase change, deformation and failure of the material are determined by analyzing the evolution mechanism of physical fields such as a temperature field, a concentration field, a stress field and a strain field of the material under an abnormal condition, so that alloy material parameters, microstructure parameters and a constitutive model are obtained.

(6) Based on the stable phase and metastable phase composition of the multi-element material, the physical property thermodynamic property of each phase, the alloy material parameters and the constitutive model, establishing a quantitative relation model among the material components, the supernormal condition, the microstructure and the performance by means of a deep learning technology; the function of constructing the model is to guide the material composition design and the ultrasonic continuous casting process design.

(7) And (3) aiming at maximizing the strength, toughness and plasticity of the ultrasonic continuous casting profile master alloy, gradually refining, searching and screening in a parameter space of a quantitative relation model, and verifying and selecting and optimizing the material components by combining experiments.

In advanced metal material design and optimization, the material parameters include phase composition, physical properties including specific heat, density, coefficient of thermal expansion, elastic constant, viscosity/diffusivity, surface tension, thermal conductivity, poisson's ratio, young's/shear/bulk modulus, stacking fault energy, degree of mismatch, etc., solidification parameters including secondary dendrite wall spacing, cooling curve, solidification path, casting strength, etc., and mechanical properties including heat treatment strength, yield strength, tensile strength, creep rupture life, fracture toughness, etc. The alloy microstructure parameters refer to phase properties, phase compositions, phase proportions, grain size distribution, interface compositions, interface types, interface type proportions, interface topological relations and the like of constituent materials, and interfaces comprise types such as surfaces, grain boundaries, phase boundaries, internal grain boundaries and the like.

Step two, designing and optimizing a target profile die, namely accurately evaluating the non-uniformity and the non-synchronism of the profile section shrinkage deformation, the surface contact and the heat dissipation conditions by means of numerical calculation and analysis of an ultrasonic continuous casting process according to the properties of metal materials, an ultrasonic solidification mechanism and the shape requirements of the target profile, and designing and optimizing the hole shape and the taper of the inner wall of the profile die; based on the shape and performance requirements of the section bar and the material composition, the inner wall of the continuous casting mold is designed and optimized and is used as an ultrasonic continuous casting mold for producing the section bar.

The design and optimization of the target profile die comprises the following steps:

(1) According to the service environment and the actual use performance requirements of the profile, determining shape control parameters such as the cross section shape SS, the shape precision SA, the surface roughness SR, the axial consistency AC and the like of the target profile; and determining a process parameter range and working condition environment parameters according to the ultrasonic continuous casting equipment and working condition conditions, wherein the process parameters comprise a crystallizer inlet temperature Tin, a blank drawing speed Vcd, a blank drawing traction force Fp and the like, and the working condition environment parameters comprise an environment temperature T0, a crystallizer length L0, a crystallizer heat dissipation coefficient h_gold, an air cooling heat dissipation coefficient h_spray, a surface emission coefficient eps_s and the like.

(2) Deriving solid phase parameters, liquid phase parameters and liquid-solid phase transformation parameters required by the ultrasonic continuous casting process simulation in the first step, wherein the solid phase parameters comprise solid phase heat capacity Cp_S, solid phase heat conductivity k_S, solid phase density rho_S, solid phase Poisson ratio nu, solid phase Young' S modulus E, solidus expansion coefficient delta_S and the like, the liquid phase parameters comprise liquid phase heat capacity Cp_L, liquid phase heat conductivity k_L, liquid phase density rho_L, liquidus expansion coefficient delta_L and the like, and the liquid-solid phase transformation parameters comprise liquid-solid phase transformation temperature T_m, phase transformation zone half-temperature width dT, phase transformation latent heat dH and the like; the ultrasonic continuous casting used abnormal condition multi-element alloy system phase diagram and material composition, abnormal condition, microstructure and quantitative relation model between performance all contain solid phase parameter, liquid phase parameter and liquid-solid phase change parameter.

(3) Three-dimensional modeling is carried out according to the section shape SS of the section based on the parameters in the step (2), the length of the model is L0 multiplied by 3.5 of the crystallizer, a three-dimensional fluid heat transfer equation, a liquid-solid phase change state equation and a thermal expansion equation are adopted for carrying out steady state solving, the change rule from the axial initial crusting position to the radial shrinkage rate of the solid phase shell at the outlet of the crystallizer is obtained, and the hole shape and the circumferential taper curved surface of the continuous casting mold in the crystallizer are optimized within the technological parameter range; the change rule from the axial initial crust position to the radial shrinkage rate of the solid phase shell at the outlet of the crystallizer is used for optimizing and determining the optimal hole shape and the optimal circumferential taper curved surface of the ultrasonic continuous casting section mould to obtain the section shape nc_SS of the continuous casting section at the outlet of the crystallizer.

(4) And determining the optimal hole shape and the optimal circumferential taper curved surface of the ultrasonic continuous casting section mould by taking the air gap ratio AGR <5% between the solid-phase shell and the mould wall surface in the crystallizer and the shape retention coefficient CC >95% of the continuous casting mould as targets, and simultaneously obtaining the section shape nc_SS of the continuous casting section at the outlet of the crystallizer.

(5) And carrying out continuous casting process simulation by using the optimal process parameters to obtain parameters such as the outlet temperature nc_T_out of the crystallizer, the liquid core length nc_L1 of the section bar, the liquid core tip temperature nc_T_p, the thickness nc_dR of the solid phase shell of the outlet of the crystallizer and the like, and extracting the three-dimensional special-shaped solid-liquid interface SLI of the section bar so as to establish the solid-liquid two-phase three-dimensional model SLM. (4) And determining the optimal hole shape and the optimal circumferential taper curved surface of the ultrasonic continuous casting section mould to obtain the section shape nc_SS of the continuous casting section at the outlet of the crystallizer. The ultrasonic continuous casting mold design is completed. (5) Based on the step (4), continuous casting process simulation is carried out to obtain a solid-liquid two-phase three-dimensional model SLM which is used for subsequent modal harmonious response analysis.

The air gap ratio agr=1-a_mix/a_wall, wherein a_mix is the overlapping area of the inner wall surface of the mold in the crystallizer and the outer surface of the solid phase shell, and a_wall is the inner wall surface area of the mold in the crystallizer. The shape-preserving coefficient cc=1-std (D)/mean (D), d=dist (samp (nc_ss, N) -samp (SS, N)), nc_ss is the sectional shape at the exit of the continuous casting section crystallizer, SS is the section sectional shape, samp () is the constant central angle sampling function, N is the number of sampling points, dist () is the vector length calculation function, std () is the standard deviation function, and mean () is the average function. The air gap rate is used for controlling the interface thermal resistance between the ultrasonic continuous casting section bar and the inner wall of the die, thereby affecting the wall thickness of the solid-phase shell at the outlet of the crystallizer and the liquid-phase cooling curve and affecting the final-state organization of the ultrasonic continuous casting.

Thirdly, designing and optimizing an ultrasonic continuous casting process, establishing a quantitative relation model among parameters of an ultrasonic continuous casting process system by adopting a mathematical modeling and deep learning quantitative modeling method based on a large amount of ultrasonic solidification test, sound field detection and process numerical calculation data, and determining core process parameters by performing space inversion analysis on the model parameters; based on the material composition, the mould and the ultrasonic solidification mechanism, the continuous casting process parameters are designed and optimized, and the ultrasonic continuous casting process is used for producing the section bar.

The ultrasonic continuous casting process design and optimization as shown in fig. 4 comprises the following steps:

(1) According to the ultrasonic solidification mechanism, a large number of process experiments and high-temperature solution sound field detection data, quantitative relations [ MGS, EPS, DG ] = F_med4irh (USCI, USCR, USCH) and alloy cavitation threshold CT between the average size MGS of matrix grains, the average size EPS of reinforced phases, the dispersion DG of reinforced phases, the ultrasonic cavitation intensity USCI, the liquid phase cavitation rate USCR and the cavitation uniformity USCH are determined.

(2) Based on cavitation threshold CT and measured cavitation intensity USCI, under the condition that an ideal vibration mode is obtained in the whole technological parameter range through sound-flow-solid coupling calculation of the ultrasonic continuous casting technological process, the vibration applying position AVP of the wall surface of the solid-phase shell and the vibration amplitude WVA of the inner wall surface are obtained, the solid-liquid phase ultrasonic sound pressure SLIP and the solid-phase amplitude SVA of the solid-liquid phase area are carried out, the contact stress FC and the actual contact area AC are carried out between the surface of the solid-phase shell and the inner wall surface of the mould, and parameters such as the maximum ultrasonic cavitation intensity USCI, the liquid-phase cavitation rate USCR, the cavitation uniformity USCH, the maximum sound pressure amplitude USP, the sound pressure uniformity USPH, the maximum sound flow speed USV, the flow speed uniformity USVH and the like are carried out in the liquid-phase cavity.

(3) The quantitative relation [ FC, AC ] = F_fa4pa (AVP, WVA, vcd, tin) among the contact stress FC, the actual contact area AC, the vibration applying position AVP of the solid-phase shell wall surface, the outer wall surface amplitude WVA, the continuous casting blank drawing speed Vcd and the crystallizer inlet temperature Tin is established by a mathematical modeling and deep learning quantitative modeling method.

(4) Quantized relations between solid-liquid two-phase region liquid-phase ultrasonic sound pressure SLIP and solid-phase amplitude SVA and solid-phase shell wall vibration position AVP, outer wall amplitude WVA, continuous casting drawing speed Vcd and crystallizer inlet temperature Tin [ SLIP, SVA ] =f_pa4pa (AVP, WVA, vcd, tin); quantized relations [ USCI, USCR, USCH ] =f_ irh4pv (USP, USPH, USV, USVH) between maximum ultrasonic cavitation intensity USCI, liquid cavitation rate USCR and cavitation uniformity USCH in the profile liquid cavity and maximum sound pressure amplitude USP, sound pressure uniformity USPH, maximum sound flow velocity USV and flow velocity uniformity USVH; and the quantized relationship [ USP, USPH, USV, USVH ] =f_pv4pa (AVP, WVA, vcd, tin) between the maximum sound pressure amplitude USP, sound pressure uniformity USPH, maximum sound flow velocity USV, and flow velocity uniformity USVH in the profile liquid-phase cavity and the solid-phase shell wall vibration position AVP, outer wall amplitude WVA, continuous casting drawing speed Vcd, and crystallizer inlet temperature Tin.

(5) The quantized relationship [ MGS, EPS, DG ] =f_med 4pavt (AVP, WVA, vcd, tin) between the ultrasonic continuous casting profile base grain average size MGS, the strengthening phase average size EPS, the strengthening phase dispersion DG and the solid phase shell wall vibration position AVP, the outer wall amplitude WVA, the continuous casting drawing speed Vcd, and the crystallizer inlet temperature Tin was established from f_med4irh, f_ irh4pv, and f_pv4pa.

(6) And carrying out inversion analysis on the output parameters of the full parameter space on F_med4pavt according to the average size opt_MGS, the average size opt_EPS and the dispersion opt_DG of the optimal matrix grains of the continuous casting profile, and determining the amplitude [ min_ WVA, max_ WVA ] of the outer wall surface of the ultrasonic continuous casting process parameter range so as to guide the design of an ultrasonic vibration system to realize quantitative regulation and control from the input end to the output end of the ultrasonic continuous casting process system. The quantitative regulation and control specifically means that the ultrasonic continuous casting hardware equipment can ensure that the input parameters of the process system can accurately regulate and control the output parameters.

The cavitation threshold is determined by parameters such as ambient pressure, temperature, boiling point, viscosity of liquid, surface tension of liquid, gas type and quantity of liquid, ultrasonic frequency and the like; the cavitation intensity is determined by parameters such as liquid viscosity, surface tension, vapor pressure, temperature and the like.

The ultrasonic continuous casting process acoustic-flow-solid coupling calculation method considers acoustic loss in ultrasonic cavitation and solidification process and comprises the following steps:

(1) In the capacity range of continuous casting equipment, orthogonality and uniformity are taken as principles, continuous casting blank drawing speed Vcd, crystallizer inlet temperature Tin, ultrasonic vibration applying position AVP and solid phase outer wall surface amplitude WVA are taken as independent variables, contact stress FC and actual contact area AC between the solid phase shell surface and the die inner wall surface are taken as dependent variables, and the maximum ultrasonic cavitation intensity USCI, the liquid phase cavitation rate USCR, cavitation uniformity USCH, the maximum sound pressure amplitude USP, sound pressure uniformity USPH, the maximum sound flow speed USV, flow speed uniformity USVH and the like in a liquid phase cavity are taken as dependent variables, so that an experimental parameter table is designed.

(2) And obtaining a solid-liquid two-phase three-dimensional model SLM_VT according to the blank drawing speed Vcd and the crystallizer inlet temperature Tin in the experimental parameter table by using the continuous casting process simulation method in the step two.

(3) And (3) carrying out grid division on the solid-liquid two-phase three-dimensional model SLM_VT by using tetrahedral or hexahedral grids, wherein the grid size is slightly smaller than dR/5, and setting a solid phase region and a liquid phase region of the model respectively by using solid phase and liquid phase material parameters.

(4) The solid phase adopts a solid mechanical module, the liquid phase adopts a thermal viscous acoustic module, a solid-liquid interface adopts an acoustic-structural coupling equation to solve a wave equation, the inner wall surface of a casting mould in a crystallizer is fixed with the other end surface of the model, the natural frequency is solved near the fundamental frequency f0=20 kHz, and the optimal vibration mode VM and the excitation frequency Vf are selected by taking the vibration mode symmetry, no swing and no distortion as the standard.

(5) And carrying out harmonic response analysis on the optimal vibration mode VM according to the ultrasonic vibration applying position AVP and the solid phase outer wall surface amplitude WVA in the experimental parameter table, and obtaining the contact stress FC and the actual contact area AC between the solid phase shell surface and the die inner wall surface through the post-treatment of the simulation result, wherein the parameters such as the maximum ultrasonic cavitation intensity USCI, the liquid phase cavitation rate USCR, the cavitation uniformity USCH, the maximum sound pressure amplitude USP, the sound pressure uniformity USPH, the maximum sound flow speed USV, the flow velocity uniformity USVH and the like are obtained in the liquid phase cavity.

The acoustic loss is determined by factors such as thermal viscosity, heat conduction, turbulence dissipation, absorption and scattering of sound waves by solid-liquid interfaces, suspended particles, cavitation bubble boundaries and the like of the melt.

The mathematical modeling and deep learning quantitative modeling method comprises the following steps:

(1) Carrying out curve or surface regression analysis on the process data to be modeled by adopting a linear function, an exponential function, a Fourier series, a Gaussian function, a polynomial, a power function, a sine function and a custom function, and carrying out the fitting goodness R ² >And 0.95, and carrying out quantitative relation modeling by adopting a mathematical modeling mode.

(2) And carrying out structural arrangement on the multiple discrete independent parameters according to the input parameters, the intermediate parameters and the output parameters, analyzing the spatial distribution state of the input parameters, cleaning conflict points, outliers and the like by taking orthogonality uniformity as a principle, and carrying out normalization processing on all the process parameters to obtain normalized structural process data.

(3) According to the process data dimension, the nonlinearity and the coupling degree between the data, an open source deep learning framework is adopted to select the network layer type, an activation function is used to set the input layer dimension and the data type, the hidden layer number, the hidden layer neuron number, the output layer dimension and the data type, and the deep learning neural network structure is designed.

(4) According to the data characteristics and the network structure, selecting an optimizer, a loss function and an evaluation function to compile and train the deep neural network, and obtaining a process parameter quantization model with the fitting goodness of higher than 0.95 by optimizing parameters such as the number of hidden layers of the network, the network type, the number of neurons, the learning rate, the number of training steps and the like.

(5) The neural network prediction result of the single-dimension input parameter and the actual measurement data of the process experiment are compared and analyzed by adopting a control variable method aiming at the quantitative relation model, the relative error and the absolute error between any input and any output are determined, and the accuracy and the reliability of the quantitative relation model are ensured through model parameter space analysis, process parameter inversion and experimental verification.

Step four, designing and optimizing an ultrasonic continuous casting vibration system, and based on an approximate ultrasonic continuous casting section ultrasonic vibration applying, vibration measuring, sound field detecting and abrasion testing system, obtaining ultrasonic data such as ultrasonic vibration-amplitude pre-tightening-contact blocking-modal phase and the like in an ultrasonic continuous casting process system and a quantitative relation model thereof, designing and optimizing the ultrasonic continuous casting vibration system; based on the requirement of an ultrasonic continuous casting process system on ultrasonic vibration capability, an ultrasonic vibration system is designed and optimized and is used for precisely vibrating in the process of producing the profile.

The ultrasonic continuous casting vibration system design and optimization comprises the following steps:

(1) The method is characterized in that a cylinder is adopted to drive a constant-pressure sliding contact vibrating wall type ultrasonic vibration scheme, a high-temperature ultrasonic vibration applying, vibration measuring and acoustic field detecting system of a section bar full true or approximate or simplified structure is built, orthogonality and uniformity are taken as principles, one-dimensional ultrasonic with the power of a transducer P0 is taken as independent variables based on pretightening force F, ultrasonic power P, vibration applying amplitude A, ultrasonic phase PH, contact area CA and section bar temperature Tb, experimental points are designed by taking solid phase outer wall surface amplitude WVA, amplitude changing rod end temperature rise Ta and vibration applying system frequency offset Fa as dependent variables, and real-time change curve data of related parameters are obtained through a large number of normal-temperature and Gao Wenshi vibration and wall surface vibration measuring experiments.

(2) Preprocessing the acquired high-frequency data by means of filtering and spectrum analysis technology, establishing a quantitative relation model [ WVA, AVP, ta, fa ] = F_ap4fpa (F, P, A, PH, CA, tb) between the amplitude WVA of the solid phase outer wall surface of the section bar, the position AVP of the maximum amplitude, the amplitude max_A of the amplitude varying bar, the frequency offset Fa of the vibration applying system and the pretightening force F, the ultrasonic power P, the vibration applying amplitude A, the ultrasonic phase PH, the contact area CA, the section bar temperature Tb by means of mathematical modeling and deep learning, analyzing the parameter space of the F_ap4fpa model, and determining the maximum ultrasonic power max_P, the maximum vibration applying amplitude max_A, the maximum pretightening force max_F, the optimal contact area opt_CA, the maximum amplitude varying bar end max_Ta and the frequency offset max_Fa of the maximum vibration applying system by means of the section bar solid phase maximum wall surface amplitude lower boundary min_ WVA and the upper boundary max_ WVA.

(3) Designing the top end shape of the amplitude transformer according to the optimal contact area opt_CA; selecting a compressor, a pre-tightening cylinder and determining the material of an amplitude transformer according to the maximum pre-tightening force max_F; determining an amplification factor Xt of the amplitude transformer according to the maximum vibration amplitude max_A; determining an ultrasonic vibrator cooling scheme according to the maximum amplitude rod end temperature rise max_Ta; determining the center frequency CF and the bandwidth dF of the ultrasonic transducer according to the frequency deviation max_Fa of the maximum vibration applying system; and determining an ultrasonic dimension Dn according to the maximum ultrasonic power max_P, if max_P is larger than P0, letting Dn=ceil (max_P/P0), wherein ceil () is an upward rounding function, the multidimensional ultrasonic vibrators are circumferentially arranged along the section bar, and the multidimensional ultrasonic phases PPn (n=1-Dn) are determined according to the maximum position of the solid phase optimal vibration mode amplitude, so that the solid phase amplitudes excited by the vibrators are mutually enhanced instead of being inhibited.

(4) Designing and customizing an ultrasonic transducer and an amplitude transformer, selecting and matching a compressor and a pre-tightening cylinder, selecting and matching a vibrator cooling system, and performing ultrasonic power, frequency and multidimensional ultrasonic phase matching test.

(5) And (3) carrying out a high-temperature abrasion experiment by adopting a customized ultrasonic continuous casting vibration system, establishing a quantized relation CA=F_c4tfplatv (t, F, P, A, PH, CA0, tb, vcd) between a contact area CA and a use time t, a pretightening force F, ultrasonic power P, vibration amplitude A, ultrasonic phase PH, an initial contact area CA0, a profile temperature Tb and a continuous casting blank drawing speed Vcd, and carrying out parameter inversion evaluation on the F_c4tfplatv in a contact area parameter range [ min_CA max_CA ] to determine the replacement period of the variable-amplitude rod.

(6) And taking the outlet temperature nc_T_out of the crystallizer as a reference, and determining the sliding friction resistance Fr=mu_c.C.AC of the section bar and the mold by experimental actual measurement of the high-temperature dynamic friction coefficient mu_c of the ultrasonic continuous casting section bar and the mold, wherein the contact stress FC and the actual contact area AC of the section bar and the mold are determined by calculation according to a quantization model F_fa4pa. By using the vibration drag reduction and stabilization principle, the time fluctuation rate TFR of the friction resistance Fr is controlled by means of f_fa4pa, wherein the time fluctuation rate tfr=std (fr_t)/mean (fr_t), fr_t is a time sequence of Fr, std () is a standard deviation function, and mean () is a mean function.

Fifthly, implementing an ultrasonic continuous casting process and controlling the process, based on a continuous casting machine, ultrasonic vibration and a process measurement and control device, integrating an ultrasonic continuous casting process system quantization model and an advanced sensing and process control technology, constructing a fully closed loop intelligent control system of the ultrasonic continuous casting process equipment-process-profile shape, and ensuring stable and efficient profile production; based on the materials, the mould, the process and the ultrasonic system, an ultrasonic continuous casting process method is adopted to produce the metal section, and intelligent process control is carried out on the process, so as to produce the metal section meeting the design requirements.

The ultrasonic continuous casting process implementation and process control comprise the following steps:

(1) Determining a process control parameter range, and establishing a quantization relation [ MGS, EPS, DG ] = F_med4fpax (F, P, A, PH, CA, tb, vcd, tin) among an ultrasonic continuous casting profile matrix grain average size MGS, a strengthening phase average size EPS, a strengthening phase dispersion DG, a pretightening force F, an ultrasonic power P, a vibration amplitude A, an ultrasonic phase PH, a contact area CA, a profile temperature Tb, a continuous casting drawing speed Vcd and a crystallizer inlet temperature Tin according to F_med4pavt and F_ap4fpa; and carrying out full-parameter space output parameter inversion analysis on F_med4fpax according to the average size opt_MGS, the average size opt_EPS and the dispersion opt_DG of the reinforced phase of the optimal matrix crystal grain of the continuous casting profile, and determining the pretightening force [ min_F, max_F ], the ultrasonic power [ min_P, max_P ], the contact area [ min_CA, max_CA ], the profile temperature [ min_Tb, max_Tb ], the continuous casting drawing speed [ min_Vcd, max_Vcd ] and the crystallizer inlet temperature [ min_tin, max_tin ].

(2) Determining a process control logic framework, controlling the temperature rise Ta of the variable amplitude rod end through a vibrator cooling system according to F_ap4fpa and F_med4fpax, automatically tracking and compensating the frequency deviation Fa of a vibration applying system through an ultrasonic power supply, stably controlling the vibration applying amplitude A and the ultrasonic phase PH, controlling the output power of the ultrasonic power supply through setting the vibration applying amplitude A and the ultrasonic phase PH of the ultrasonic power supply and pretightening force F, further stably controlling the vibration applying amplitude WVA of the outer wall surface of a solid phase and the vibration applying position AVP of the solid phase, ensuring the stability of the friction resistance Fr, the pulling traction force Fp and the pulling speed Vcd between the profile and a mould, and finally realizing the stable control of the average grain size MGS, the average reinforced phase size EPS and the dispersion DG of the ultrasonic profile by combining a magnetic control ultrasonic turbulence inhibiting technology.

(3) The ultrasonic continuous casting process control online neural network is constructed and deployed, according to F_med4irh, F_fa4pa, F_pa4pa, F_ irh pv, F_pv4pa, F_me4pavt, F_ap4fpa, F_c4tfplatv, F_me4fpax equivalent relation model, the pretightening force F, ultrasonic power P, vibration amplitude A, ultrasonic phase PH, contact area CA, profile temperature Tb, continuous casting blank pulling speed Vcd, crystallizer inlet temperature Tin, solid phase outer wall vibration position AVP, solid phase outer wall surface amplitude WVA are used as process control input parameters, the amplitude rod end temperature rise Ta, vibration system frequency offset Fa, blank pulling traction force Fp are used as basic control parameters, the solid-liquid two-phase region liquid phase ultrasonic sound pressure SLIP and solid phase amplitude SVA, the contact stress FC and actual contact area AC between the solid phase shell surface and the inner wall surface of the mould are used as basic control parameters, the method comprises the steps of constructing an integrated ultrasonic continuous casting process control online deep neural network by taking the maximum ultrasonic cavitation intensity USCI, the liquid cavitation rate USCR, the cavitation uniformity USCH, the maximum sound pressure amplitude USP, the sound pressure uniformity USPH, the maximum sound flow speed USV and the flow speed uniformity USVH in a liquid cavity as process control intermediate parameters, taking the average grain size MGS, the average reinforced phase size EPS and the reinforced phase dispersion DG of a profile substrate as process control indexes, adopting a local cloud host to deploy the deep neural network in a service mode, and adopting a network connection mode with high reliability and low delay to carry out data and instruction transmission with an ultrasonic power supply, a pre-compaction pressure controller, a magnetic field controller, a profile continuous casting machine, a multi-channel temperature collector, a high-precision laser vibrometer and other sensing monitoring and process control devices, so as to ensure stable, efficient and traceable process control.

(4) Selecting a proper equipment operation mode to carry out continuous production according to the stability, the energy consumption cost and the production efficiency of an ultrasonic continuous casting process system, wherein the operation mode comprises a standard self-adaptive mode, a full-automatic performance mode and an energy efficiency control mode, the standard self-adaptive mode is set according to a matrix grain average size MGS, a strengthening phase average size EPS and a strengthening phase dispersion DG which are slightly higher than the recommended standard of the profile, and the ultrasonic continuous casting process optimization control is carried out by taking the energy consumption cost and the production efficiency as targets, so that the ultrasonic continuous casting process system is suitable for the production stage of common ultrasonic continuous casting profiles; the full-automatic performance mode is used for optimally controlling the average size MGS of matrix grains, the average size EPS of reinforced phases and the dispersion DG of reinforced phases on the premise of ensuring the stability of the equipment in the equipment capacity range, and is suitable for the research and development stage of novel ultrasonic continuous casting profiles; the energy efficiency control mode is based on the common continuous casting process, aims at realizing the maximum energy efficiency ratio of the ultrasonic continuous casting process control model F_med4fpax, and is suitable for upgrading the performance of the common continuous casting profile.

(5) The magnetic control turbulence suppression technology is to apply a powerful static magnetic field or a modulated electromagnetic field to the cavitation area of the liquid cavity of the ultrasonic continuous casting section so as to realize the purpose of suppressing the acoustic turbulence and strengthening the ultrasonic cavitation effect. The ultrasonic cavitation effect refers to the effects of local instantaneous high temperature, high-speed microjet, strong shock wave and the like generated by collapse of cavitation bubbles in a high-temperature solution under the action of a high-energy ultrasonic field. The cavitation mechanical effect has the most direct and obvious effect on the solidification process of the metal melt, and mainly depends on two points, namely high-speed microjet formed by asymmetric collapse of cavitation bubbles due to wall surface, gravity, proximity degree of adjacent bubbles and the like, and strong shock wave caused by continuous low-frequency coherence collapse of residual cavitation bubble groups generated by collapse fission of the cavitation bubbles, wherein the pulse pressure generated by the latter is several times greater than that of the former, and the strong turbulence effect caused by microjet with the flow velocity of about 100m/s is caused, so that in the high-temperature melt, huge and turbulent temperature density sound velocity gradient, heat conduction with heat viscosity and relaxation of the microscopic process can cause strong nonuniform refraction, scattering and attenuation of ultrasonic waves, cavitation shielding limit range and uniformity of the cavitation are caused, and the ultrasonic solidification process control effect is seriously influenced. The magnetic control turbulence suppression means that in a controllable magnetic field, high-speed micro-jet of the metal melt can generate high-density vortex, and ampere force applied to the charged melt suppresses relative movement of the charged melt. The modulated magnetic field can change the solidification path of the ultrasonic continuous casting section bar by changing the energy state and stability of the magnetic phase, thereby influencing the final state structure of the ultrasonic continuous casting section bar.

The ultrasonic continuous casting process measurement and control device shown in figure 3 is arranged between the tip end of the core and the outlet of the crystallizer, the ultrasonic continuous casting process measurement and control device consists of a main control workstation, a high-precision laser vibration meter, a high-fidelity noise pickup, an infrared thermometer at the outlet of the crystallizer, an infrared thermometer at the ultrasonic vibration applying position, an ultrasonic vibrator amplitude transformer thermometer, an ultrasonic vibrator transducer thermometer, a magnetic field generator thermometer, an environmental temperature acquisition instrument and other signal acquisition devices, and is provided with communication control interfaces comprising RS232, RS422, RS485, RJ45, USB, digital or analog I/O and the like, and is connected with equipment such as an ultrasonic power supply, a pre-compression force device, a magnetic field generation device, a continuous casting machine, a cooler, a water cooling spray device and the like, the monitoring signals include solid-phase shell wall surface amplitude WVA, noise signal NS, crystallizer outlet profile temperature T_out, ultrasonic vibration position profile temperature Tb, ultrasonic vibrator amplitude transformer temperature T_h, ultrasonic vibrator transducer temperature T_t, magnetic field generator temperature T_mf, environment temperature T0 and the like, and the control signals include an ultrasonic power supply related switch USPS, a real-time frequency frt, vibration amplitude A, ultrasonic power P, ultrasonic phase TH, transducer air cooling air flow AFR, amplitude transformer water cooling liquid flow LFR, pre-compression pressure related switch PT, pressure F, a magnetic field related switch MF, magnetic field intensity MFI, phase MTH, air cooling air flow MAFR, a continuous casting machine related switch CCR, continuous casting temperature Tin, blank pulling traction force Fp, blank pulling speed Vcd, primary spraying water flow SWFR, a vibration meter related switch VM, a sampling rate VSR, a sampling duration, a sampling time, a noise pickup related switch NMP and a sampling rate NMP.

The main control workstation provides an ultrasonic continuous casting process control online neural network deployment environment and a process system basic parameter control service, wherein the ultrasonic amplitude transformer temperature rise Ta realizes closed-loop control through the ultrasonic vibrator amplitude transformer temperature T_h and the amplitude transformer water cooling liquid flow LFR; frequency deviation Fa=vibration frequency Vf-real-time frequency frt of the vibration system, and automatic frequency tracking compensation is performed through an ultrasonic power supply; the temperature rise Tc of the ultrasonic transducer realizes closed-loop control through the temperature T_t of the ultrasonic transducer and the air cooling air flow AFR of the transducer; the temperature rise Tmag of the magnetic field generator realizes closed-loop control through the temperature T_mf of the magnetic field generator and the air cooling air flow MAFR of the magnetic field generator.

The contact area CA of the ultrasonic amplitude transformer and the wall surface of the profile is evaluated by means of F_c4tfplatv through historical use time t, pretightening force F, ultrasonic power P, vibration amplitude A, ultrasonic phase PH, initial contact area CA0, profile temperature Tb and continuous casting blank drawing speed Vcd, and the ultrasonic continuous casting profile primary spray water flow SWFR is independently compensated and regulated by controlling the profile vibration position cooling speed optimization contact condition.

The stability control of the blank pulling speed Vcd of the ultrasonic continuous casting machine is realized by controlling and regulating the frictional resistance between the profile and the die and the blank pulling traction force Fp.

The ultrasonic continuous casting section solid phase type shell wall surface amplitude WVA is calculated, evaluated and feedback controlled according to F_ap4fpa through pretightening force F, vibration amplitude A, ultrasonic power P, ultrasonic phase TH, contact area CA and section temperature Tb.

The sampling rate VSR of the laser vibration meter and the sampling rate NMSR of the noise pickup are larger than 10 xvf, the wall vibration signal adopts high-pass filtering to extract high-frequency vibration amplitude, and the cut-off frequency is larger than 1kHz; according to real-time noise monitoring analysis, abnormal conditions such as low-frequency jitter, beat, swing, collision and the like are identified, and vibration parameters are regulated and controlled to avoid under the condition that the vibration amplitude WVA of the solid-phase shell wall surface is not changed; the ultrasonic continuous casting process measurement and control device has a data service interface and remote access capability, provides an industrial Internet connection function, and allows process data to be downloaded and online neural network to be updated.

Step six, carrying out post-treatment on the continuous casting section, cutting the ultrasonic continuous casting section according to the application scene and actual requirements of the specific target section, carrying out heat treatment such as annealing normalizing, quenching tempering and the like, carrying out surface treatment such as powder spraying, wire drawing, film coating and the like, and carrying out mechanical processing such as drilling, slot milling, bending and the like, thereby finally obtaining a high-quality metal section product. And carrying out post-treatment on the produced metal continuous casting section bar to obtain the high-performance metal section bar which is used for a target service scene.

The quantitative modeling flow of the intelligent ultrasonic continuous casting process system of the metal section is shown in figure 4, firstly, according to ultrasonic solidification mechanism and a large amount of process experiments and high-temperature solution sound field detection data, the quantitative relation between the average size MGS of matrix grains, the average size EPS of reinforced phases, the dispersion DG of reinforced phases, the ultrasonic cavitation intensity USCI, the liquid phase cavitation rate USCR and the cavitation uniformity USCH [ MGS, EPS, DG ] =F_med 4irh (USCI, USCR, USCH) is established, then, by means of the acoustic-flow-solid coupling calculation of the ultrasonic continuous casting process, the quantitative relation between the maximum ultrasonic cavitation intensity USCI, the liquid phase cavitation rate USCR, the cavitation uniformity USCH, the maximum sound pressure amplitude USP, the sound pressure uniformity USPH, the maximum sound flow speed USV and the flow speed uniformity USVH [ USCI, USCR, USCH ] =F_ irh4pv (USP, USPH, USV, USVH) in the liquid phase cavity of the section is established, and quantized relations [ USP, USPH, USV, USVH ] = f_pv4pa (AVP, WVA, vcd, tin) between maximum sound pressure amplitude USP, sound pressure uniformity USPH, maximum sound flow velocity USV and flow velocity uniformity USVH in the section liquid-phase cavity and solid-phase shell wall vibration position AVP, outer wall amplitude WVA, continuous casting drawing speed Vcd and crystallizer inlet temperature Tin, quantized relations [ FC, AC ] = f_fa4pa (AVP, WVA, vcd, tin) between solid-phase shell surface and mold inner wall vibration position AVP, actual contact area AC and solid-phase shell wall vibration position AVP, outer wall amplitude WVA, continuous casting drawing speed Vcd and crystallizer inlet temperature Tin, quantized relations [ FC, AC ] = f_fa4pa (AVP, WVA, vcd, tin), and solid-liquid two-phase region liquid-phase ultrasonic sound pressure SLIP and solid-phase amplitude SVA and solid-phase shell wall vibration position AVP, outer wall amplitude WVA, the quantized relation between the continuous casting drawing speed Vcd and the crystallizer inlet temperature Tin [ SLIP, SVA ] =F_pa4pa (AVP, WVA, vcd, tin), and the quantized relation model [ WVA, AVP, ta, fa ] =F_ap4fpa (F, P, A, PH, CA, tb) between the contact area CA and the use time t, the pre-tightening force F, the ultrasonic power P, the applied amplitude A, the ultrasonic phase PH, the initial contact area CA0, the section bar temperature Tb and the continuous casting drawing speed Vcd is established according to a large number of normal temperature and Gao Wenshi vibration and wall vibration measurement experiments, F, P, a, PH, CA0, tb, vcd) to evaluate horn life, then establishing ultrasonic continuous casting profile matrix grain average size MGS, strengthening phase average size EPS, strengthening phase dispersion DG and solid phase shell wall vibration position AVP, outer wall amplitude WVA, quantitative relation between continuous casting drawing speed Vcd and crystallizer inlet temperature Tin [ MGS, EPS, DG ] = f_med4pavt (AVP, WVA, vcd, tin), finally establishing ultrasonic continuous casting profile matrix grain average size MGS, strengthening phase average size EPS, strengthening phase dispersion and pretightening force F, ultrasonic power P, applied amplitude a, ultrasonic phase PH, contact area CA, profile temperature Tb, ultrasonic continuous casting profile matrix grain average size MGS, strengthening phase dispersion degree EPS, pretightening force F, ultrasonic vibration amplitude a, ultrasonic phase PH, contact area CA, profile temperature Tb, ultrasonic continuous casting profile matrix grain average size MGS, strengthening phase dispersion degree DG, ultrasonic continuous casting profile grain average size mg, strengthening phase dispersion degree DG, solid phase distribution, and the quantitative relation [ MGS, EPS, DG ] =F_med 4fpax (F, P, A, PH, CA, tb, vcd, tin) between the continuous casting and drawing speed Vcd and the crystallizer inlet temperature Tin is used for completing the quantitative modeling of the intelligent ultrasonic continuous casting process system of the metal section.

The intelligent ultrasonic continuous casting process control logic framework of the metal section is shown in fig. 5, firstly, the subsystems of ultrasonic vibration, energy converter air cooling, amplitude transformer water cooling, pneumatic pre-tightening, magnetic field generator cooling, process monitoring, process control and the like are initialized and self-inspected, and then, the process mode is set: standard self-adapting or full-automatic performance or energy efficiency control mode, inputting target parameters: the average size of matrix grains MGS, the average size of strengthening phase EPS and the degree of dispersion DG of the strengthening phase are input into preset parameters: and inputting control parameters including a shell vibration applying position AVP, a billet traction force Fp and a continuous casting temperature Tin: the method comprises the steps of calculating ultrasonic cavitation intensity USCI, liquid phase cavitation rate USCR and cavitation uniformity USCH in a liquid cavity according to [ MGS, EPS, DG ] = F_med4irh (USCI, USCR, USCH) inversion, calculating maximum sound pressure amplitude USP, sound pressure uniformity USPH, maximum sound flow speed USV and flow speed uniformity USVH in the cavity according to [ USCI, USCR, USCH ] = F_ irh4pv (USP, USPH, USV, USVH) inversion, calculating shell wall vibration position AVP, outer wall vibration amplitude WVA, continuous casting drawing speed Vcd and crystallizer inlet temperature Tin according to [ USP, USPH, USV, USVH ] = F_pv4pa (AVP, WVA, vcd, tin) inversion, updating the drawing speed Vcd, and then automatically fine-adjusting solid phase shell wall optimal vibration position AVP, ultrasonic phase PH and vibration amplitude A according to [ WVA, AVP, ta ] = F_p 4pa (AVP, WVA, vcd, tin), calculating ultrasonic vibration amplitude, setting ultrasonic vibration data, setting the ultrasonic vibration temperature Tb, and carrying out inversion, and setting the ultrasonic vibration force, the vibration amplitude to be the profile temperature Tb; collecting the temperature T_h of an ultrasonic vibrator amplitude transformer, and controlling the water cooling liquid flow LFR of the amplitude transformer; collecting ultrasonic transducer temperature data T_t, and controlling transducer air cooling air flow AFR; acquiring profile wall amplitude data, setting a maximum wall amplitude WVA and updating; collecting temperature data T_mf of a magnetic field generator, and cooling air flow MAFR of the magnetic field generator; collecting noise signals for fault diagnosis, and adjusting process parameters to avoid low-frequency vibration; and then calculating sliding friction resistance Fr=mu_c=FC+AC according to [ FC, AC ] =F_fa4pa (AVP, WVA, vcd, tin), setting drawing traction force Fp and drawing speed Vcd according to friction resistance time fluctuation rate TFR and updating process parameters, then, according to CA=F_c4tfplatv (t, F, P, A, PH, CA0, tb, vcd), evaluating the service life of the amplitude transformer by controlling one-time spray water flow SWFR, calculating data such as transducer temperature rise Ts, amplitude transformer temperature rise Ta, vibration system frequency deviation Fa, magnetic field generator temperature rise Tmf, friction resistance fluctuation rate TFR and finally, updating and displaying parameters such as ultrasonic continuous casting real-time process, working condition environment, equipment state and the like.

According to the simulation method of the ultrasonic continuous casting process in the step two of fig. 2, the steady state numerical calculation model of the ultrasonic continuous casting process of the plate comprises parameters such as actual production condition definition materials, process, working conditions and the like, and the acoustic-flow-solid coupling calculation analysis model of the ultrasonic continuous casting process of the plate comprises parameters such as actual production condition definition materials, process, working conditions and the like, wherein the acoustic-flow-solid coupling calculation analysis result of the ultrasonic continuous casting process of the plate is shown in fig. 6, namely, the acoustic field distribution simulation result of the ultrasonic continuous casting liquid cavity of the plate is shown.

The invention has the following beneficial effects:

(1) In the intelligent ultrasonic continuous casting process of the metal profile, high-energy ultrasonic promotes dispersion of the strengthening phase, reduces the dimension of the strengthening phase, improves the distribution uniformity of the strengthening phase, and improves the mechanical properties of complex and/or large-section profiles.

(2) The magnetic control turbulence suppression technology is developed, the effect of suppressing the sound-induced turbulence by continuously collapsing shock waves of the residual cavitation groups is enhanced, and the sound conduction efficiency, the ultrasonic cavitation rate and the cavitation uniformity in the ultrasonic continuous casting cavity are improved.

(3) Based on an ultrasonic continuous casting process system quantization model and an intelligent process measurement and control device, high-quality profile high in forming precision, high in consistency, high in toughness and low in stress level is ensured to be produced efficiently and stably.

(4) The controllable high-energy ultrasonic field balances the influence of difference of internal and external cooling speeds of the section of the continuous casting section, remarkably promotes equiaxial structure of the core of the continuous casting section, and remarkably improves the uniformity of the structure and isotropy of the toughness of the continuous casting section.

(5) The controllable micron-level high-frequency ultrasonic vibration reduces the friction resistance between the wall surface of the profile and the crystallizer, improves the surface roughness of the continuous casting profile, reduces the traction force, improves the continuous casting drawing speed, and has the effects of reducing the cost and enhancing the efficiency.

(6) The high-energy ultrasonic field in the liquid core of the continuous casting section improves the fluidity and wettability of semi-solid metal, obviously reduces the loosening and shrinkage tendency of the section, and improves the yield of the continuous casting section and the quality stability of high-efficiency production.

(7) In the ultrasonic continuous casting method, the high-energy ultrasonic field improves the radial segregation of alloy components, obviously eliminates the internal stress generated by asynchronous liquid-solid phase transformation, and reduces the crack sensitivity of the ultrasonic continuous casting section.

(8) The intensity and the wear resistance of the ultrasonic vibration applying position are improved by adopting the independently controlled centralized primary water-cooling spraying, the service life of the ultrasonic amplitude transformer is effectively prolonged, and the possibility of additional damage to the surface of the profile is reduced.

(9) The intelligent ultrasonic continuous casting section core structure refining process is insensitive to material components, has strong material type adaptability, obvious effect, controllability and reliability, and has strong exemplary significance for the transformation upgrading of the continuous casting industry and the design preparation and large-scale production application of advanced materials.

The invention provides an intelligent ultrasonic continuous casting measurement and control device for metal profiles, which comprises the following components:

the acquisition module is used for acquiring core energy field parameters, shape control parameters, process parameters, working condition environment parameters, first quantization relations, alloy cavitation threshold values and Shi Zhenshi test data of the metal materials, target profile performance control indexes and solidification conditions.

And the metal material optimizing module is used for optimizing the metal material according to the target profile performance control index and the core energy field parameter of the solidification condition to obtain metal material parameters.

And the continuous casting mold optimization module is used for optimizing the continuous casting mold according to the shape control parameter, the technological parameter and the working condition environment parameter to obtain continuous casting mold parameters.

And the continuous casting process parameter optimization module is used for carrying out continuous casting process parameter optimization according to the first quantitative relation and the alloy cavitation threshold value to obtain a continuous casting process quantitative relation.

And the ultrasonic vibration system optimization module is used for optimizing the ultrasonic vibration system according to the Shi Zhenshi test data to obtain vibration parameters.

And the ultrasonic continuous casting control parameter determining module is used for determining ultrasonic continuous casting control parameters according to the metal material parameters, the continuous casting mold parameters, the continuous casting process quantization relation and the vibration applying parameters.

As an alternative embodiment, the metal material optimizing module specifically includes:

and the metal material optimizing unit is used for optimizing the metal material by taking the target profile performance control index as an objective function and utilizing a density functional theory according to the core energy field parameters of the solidification condition to obtain metal material parameters.

As an alternative embodiment, the continuous casting mold optimizing module specifically includes:

and the modeling unit is used for carrying out three-dimensional modeling according to the shape control parameter, the technological parameter and the working condition environment parameter to obtain a three-dimensional model.

And the steady state solving unit is used for carrying out steady state solving by utilizing a three-dimensional fluid heat transfer equation, a liquid-solid phase change state equation and a thermal expansion equation according to the three-dimensional model to obtain a change rule from the axial initial crusting position to the diameter shrinkage rate of the solid phase shell at the outlet of the crystallizer.

And the optimizing unit is used for optimizing the continuous casting mold according to the change rule and the technological parameters to obtain continuous casting mold parameters.

As an optional implementation manner, the continuous casting process parameter optimization module specifically includes:

The coupling calculation unit is used for performing coupling calculation according to the first quantization relation and the alloy cavitation threshold value to determine ideal vibration mode information; the first quantitative relationship is a quantitative relationship among a matrix grain average size, a strengthening phase dispersion, ultrasonic cavitation intensity, a liquid phase cavitation rate and cavitation uniformity.

A second quantization relation determining unit, configured to determine a second quantization relation according to the ideal vibration mode information by using a deep learning quantization modeling method; the second quantitative relation is the quantitative relation among the contact stress between the surface of the solid-phase shell and the inner wall surface of the die, the actual contact area, the vibration applying position of the wall surface of the solid-phase shell, the vibration amplitude of the outer wall surface, the continuous casting blank drawing speed and the inlet temperature of the crystallizer.

And the continuous casting process quantitative relation determining unit is used for determining the continuous casting process quantitative relation according to the second quantitative relation.

The invention is based on the ultrasonic solidification process regulation and control and magnetic control turbulence suppression technology, does not depend on alloy components, effectively improves the sound conduction efficiency, ultrasonic cavitation rate and uniformity of the liquid metal with the complex cavity, has the advantages of improving the surface roughness, component tissue segregation, loosening shrinkage tendency, crack sensitivity, uneven strength and toughness of the continuous casting section, and the like, can improve the continuous casting production efficiency, yield, quality and stability of the metal section with complex shape and/or large section, and promotes the transformation upgrading of the continuous casting industry and the design, preparation optimization and large-scale production and application of advanced materials. The method comprises the following steps: advanced metal material design and optimization, target profile die design and optimization, ultrasonic continuous casting process design and optimization, ultrasonic continuous casting vibration system design and optimization, ultrasonic continuous casting process implementation and process control, and continuous casting profile post-treatment. The surface quality, radial and circumferential solidification structure uniformity, comprehensive toughness and yield of the continuous casting parison are improved, and the composition segregation, stress level and crack sensitivity are reduced.

In the present specification, each embodiment is described in a progressive manner, and each embodiment is mainly described in a different point from other embodiments, and identical and similar parts between the embodiments are all enough to refer to each other. For the system disclosed in the embodiment, since it corresponds to the method disclosed in the embodiment, the description is relatively simple, and the relevant points refer to the description of the method section.

The principles and embodiments of the present invention have been described herein with reference to specific examples, the description of which is intended only to assist in understanding the methods of the present invention and the core ideas thereof; also, it is within the scope of the present invention to be modified by those of ordinary skill in the art in light of the present teachings. In view of the foregoing, this description should not be construed as limiting the invention.

Claims

1. An intelligent ultrasonic continuous casting method for metal profiles is characterized by comprising the following steps:

acquiring a metal material, a target profile performance control index, a core energy field parameter of a solidification condition, a shape control parameter, a process parameter, a working condition environment parameter, a first quantitative relation, an alloy cavitation threshold value and Shi Zhenshi test data; the first quantitative relation is a quantitative relation among the average size of matrix grains, the average size of reinforced phases, the dispersion degree of reinforced phases, the ultrasonic cavitation intensity, the liquid phase cavitation rate and the cavitation uniformity;

optimizing continuous casting process parameters according to the first quantitative relation and the alloy cavitation threshold value to obtain a continuous casting process quantitative relation;

2. The intelligent ultrasonic continuous casting method of the metal section according to claim 1, wherein the optimizing the metal material according to the target section performance control index and the core energy field parameter of the solidification condition to obtain the metal material parameter specifically comprises:

and optimizing the metal material by taking the target profile performance control index as an objective function and utilizing a density functional theory according to the core energy field parameters of the solidification condition to obtain metal material parameters.

3. The intelligent ultrasonic continuous casting method of the metal section according to claim 1, wherein the optimizing the continuous casting mold according to the shape control parameter, the process parameter and the working condition environment parameter to obtain the continuous casting mold parameter specifically comprises:

performing three-dimensional modeling according to the shape control parameters, the process parameters and the working condition environment parameters to obtain a three-dimensional model;

performing steady state solving by utilizing a three-dimensional fluid heat transfer equation, a liquid-solid phase change state equation and a thermal expansion equation according to the three-dimensional model to obtain a change rule from an axial initial crusting position to a solid phase shell diameter shrinkage rate at an outlet of the crystallizer;

4. The intelligent ultrasonic continuous casting method of the metal section according to claim 1, wherein the optimizing of continuous casting process parameters according to the first quantitative relation and the alloy cavitation threshold value to obtain the quantitative relation of the continuous casting process specifically comprises:

performing coupling calculation according to the first quantization relation and the alloy cavitation threshold value, and determining ideal vibration mode information;

determining a second quantization relation by utilizing a deep learning quantization modeling method according to the ideal vibration mode information; the second quantitative relation is a quantitative relation among contact stress, actual contact area, vibration applying position of the solid-phase shell wall surface, vibration amplitude of the outer wall surface, continuous casting blank drawing speed and inlet temperature of a crystallizer;

And determining the quantitative relation of the continuous casting process according to the second quantitative relation.

5. An intelligent ultrasonic continuous casting measurement and control device for metal profiles, which is characterized by comprising:

the acquisition module is used for acquiring core energy field parameters, shape control parameters, process parameters, working condition environment parameters, a first quantitative relation, an alloy cavitation threshold and Shi Zhenshi test data of the metal material, the target profile performance control index and the solidification condition; the first quantitative relation is a quantitative relation among the average size of matrix grains, the average size of reinforced phases, the dispersion degree of reinforced phases, the ultrasonic cavitation intensity, the liquid phase cavitation rate and the cavitation uniformity;

6. The intelligent ultrasonic continuous casting measurement and control device for metal profiles according to claim 5, wherein the metal material optimizing module specifically comprises:

7. The intelligent ultrasonic continuous casting measurement and control device for metal profiles according to claim 5, wherein the continuous casting die optimizing module specifically comprises:

the modeling unit is used for carrying out three-dimensional modeling according to the shape control parameter, the process parameter and the working condition environment parameter to obtain a three-dimensional model;

The steady state solving unit is used for carrying out steady state solving by utilizing a three-dimensional fluid heat transfer equation, a liquid-solid phase change state equation and a thermal expansion equation according to the three-dimensional model to obtain a change rule from an axial initial crusting position to the diameter shrinkage rate of the solid phase shell at the outlet of the crystallizer;

8. The intelligent ultrasonic continuous casting measurement and control device for metal profiles according to claim 5, wherein the continuous casting process parameter optimization module specifically comprises:

the coupling calculation unit is used for performing coupling calculation according to the first quantization relation and the alloy cavitation threshold value to determine ideal vibration mode information;

a second quantization relation determining unit, configured to determine a second quantization relation according to the ideal vibration mode information by using a deep learning quantization modeling method; the second quantitative relation is a quantitative relation among contact stress, actual contact area, vibration applying position of the solid-phase shell wall surface, vibration amplitude of the outer wall surface, continuous casting blank drawing speed and inlet temperature of a crystallizer;