Based on the important boundary conditions of rolling simulation including friction, heat conduction and interactionsof the workpiece and rolls, the hot continuous rolling processes of large-diameter mandrel round bar...Based on the important boundary conditions of rolling simulation including friction, heat conduction and interactionsof the workpiece and rolls, the hot continuous rolling processes of large-diameter mandrel round bar (200 mm indiameter) in 6VH-stand hot tandem mill are successfully simulated by three-dimensional coupled thermomechanicalelastoplastic finite element method (FEM). The distributions of stress, strain, temperature and the rolling force andtorque for the two-pass and four-pass continuous rolling are calculated respectively. Thus, the two and four-passroll schedules are verified, respectively. The simulation results show that it is safe to produce 200 mm round barby the two-pass (oval pass and round pass) continuous rolling on the existing equipment compared to the four-passcontinuous rolling. There are concave surfaces and increased widths occurring at the end of rolled billet due touneven deformations between the outside and inside of the workpiece as well as the free spreading close to the rollgap of the final pass.展开更多
In the process of steel tube production, continuous tube rolling is the foremost forming procedure and the critical step that decides the dimension precision and the surface quality. In the actual production of the 41...In the process of steel tube production, continuous tube rolling is the foremost forming procedure and the critical step that decides the dimension precision and the surface quality. In the actual production of the 4140 mm full floating mandrel mill in Steel Tube Branch in Baosteel, steel T91 was chosen to be the typical sample, self-made rolling force transducer and mandrel velocity testing equipment were used, and a series of comprehensive tests on rolling parameters including the rolling force and mandrel velocity were carried out. After the experiment, the friction state between rolling tube and mandrel was analyzed. The friction coefficient was calculated and the values of 0. 033 - 0. 074 in each mill were obtained. The friction coefficient increases obviously along the rolling direction.展开更多
Roller pass is one of the key factors affecting the product quality in the retained mandrel rolling process. The metal flow condition of rolling deformation area was researched using the FEA （finite element analysis...Roller pass is one of the key factors affecting the product quality in the retained mandrel rolling process. The metal flow condition of rolling deformation area was researched using the FEA （finite element analysis） software Marc. The influences of the pass bottom radius, the sidewall radius, the sidewall angle, the roller shoulder fillet radius, as well as the roller gap on the rolling process under the conditions of different friction were discussed. Based on these results, the changes of the workpiece exit width, the mandrel axial force, the rolling force, and the rolling torque associated with various parameters were determined, which would provide the basis for designing the pass and determining the rolling condition reasonably.展开更多
Optical microscope, stereomicroscope, scanning electronic microscope （SEM） and mechanical property testing were used to research the effects of different quenching temperatures on the microstructure and mechanical p...Optical microscope, stereomicroscope, scanning electronic microscope （SEM） and mechanical property testing were used to research the effects of different quenching temperatures on the microstructure and mechanical properties of the H13 mandrel steel. The results indicate that following an increase in the quenching ,the degree of alloying is enhanced due to the carbides dissolving gradually in austenite, which improves the hardenability of the specimens, as well as their room and high-temperature strength. At the same time, the fracture toughness increases due to the increment of the martensite number and the interparticle distance of impact toughness. Optimal performance Consequently,the service life of the H13 the carbides. However, extremely coarse grain and martensite can decrease the can be obtained after quenching at 1 060℃ and double tempering at 620℃mandrel steel is extended significantly.展开更多
During the process of cross wedge rolling of aluminum alloy hollow shaft, the evolution of its microstructure has an important influence on the mechanical properties of the rolled piece. In order to obtain the microst...During the process of cross wedge rolling of aluminum alloy hollow shaft, the evolution of its microstructure has an important influence on the mechanical properties of the rolled piece. In order to obtain the microstructure evolution law of aluminum alloy hollow shaft in cross wedge rolling without mandrel, a finite element model is constructed through the finite element software Deform-3D. The influences of rolling temperature, sectional shrinkage,spreading angle and forming angle on the average grain size of rolled piece are studied by numerical simulation of microstructure evolution. The cellular automata method reveals the inherent relationship between the process parameters and the evolution of the microstructure, and provides a reference for optimizing the rolling process parameters of aluminum alloy hollow shafts and improving the forming quality. The results show that the average grain size of the rolled piece increases with the increase of the rolling temperature, decreases with the increase of the sectional shrinkage,and decreases first and then increases with the increase of the spreading angle, and changes little with the increase of the forming angle.展开更多
Two new size factors of cross-section hollow coefficient and bending degree are introduced to reveal the size effect of bending forming of bimetallic composite tube.Hollow coefficient and bending degree can limit the ...Two new size factors of cross-section hollow coefficient and bending degree are introduced to reveal the size effect of bending forming of bimetallic composite tube.Hollow coefficient and bending degree can limit the commonly used bent tube to the size description range of(0,2.00).The evolution laws of the cross-section distortion forms in the hollow coefficient-bending degree interval are revealed as well as the action of the mandrel-cores on the size effect.Results show the mandrel-cores filling can expand the forming limit of the bent tube,but also bring two other forming defects of wrinkle and rupture.The identification factor(hollow coefficient multiply bending degree)provides a method for querying the cross-section distortion forms of all composite bending tubes.In the identification factor interval(0,1.00),the distribution area of bending forming defects of the composite tube is continuous.The thin-walled composite bending tube collapses when identification factor in(0,0.39),wrinkles when identification factor in[0.39,0.50),and ruptures when identification factor in[0.50,1.00).The mathematical model of size effect is derived,by which the average cross-section distortion rate is found to distribute like a radial leaf in the hollow coefficient-bending degree qualified forming space.The best forming zone is hollow coefficient 0.46-0.68,and bending degree 0.25-0.47.展开更多
This study researches the effects of the refining treatment on the microstructure and the mechanical properties of H13 mandrel steel and compares these effects with those of the conventional treatment. The results ind...This study researches the effects of the refining treatment on the microstructure and the mechanical properties of H13 mandrel steel and compares these effects with those of the conventional treatment. The results indicate that both carbide particles and grains were refined, carbide particles were uniformly distributed by the refining treatment, and therefore,the strength and toughness of H13 mandrel steel were improved. Rapid cooling after the solution treatment may inhibit intra-granular precipitation of carbide particles, which is favorable to enhancing toughness. Consequently, high- performance H13 mandrel steel can be produced by proper refining treatment.展开更多
Based on the ABAQUS explicit dynamic simulation platform,the finite element model of single stand mill with restrained mandrel was adopted to research the influence of mandrel - roller velocity ratio (MRVR),mandrel fr...Based on the ABAQUS explicit dynamic simulation platform,the finite element model of single stand mill with restrained mandrel was adopted to research the influence of mandrel - roller velocity ratio (MRVR),mandrel friction and tension between stands on rolling force.The analysis results show that when the MRVR is lower than 1,the rolling force increases obviously with the increase of MRVR and reaches the peak value when the MRVR is about 1.The rolling force increase induced by the MRVR increase is the main reason of the formation of the bulge defect on the tube head and tail at the entering and exiting stage during tube continuous rolling process by full floating mandrel mill,which can be intensified by the increase of mandrel friction coefficient.The rolling force decreases with the increase of tension.As the tension is larger, the rolling force decrease amplitude is larger.The influence of backward tension on rolling force is greater than that of forward tension distinctly.Tension control can be used to decrease the rolling force increase induced by the MRVR increase,which is imposing tension at the same time when the MRVR increases,in order to improve even eliminate the bulge defect,and enhance the tube dimension precision.展开更多
The microstructures and mechanical properties of H13 mandrels made by Baosteel and foreign companies were investigated in this study. Based on the comparison research, the processes were optimized, such as steelmaking...The microstructures and mechanical properties of H13 mandrels made by Baosteel and foreign companies were investigated in this study. Based on the comparison research, the processes were optimized, such as steelmaking, heat treatment and multiple forging processes. The quality of Baosteel mandrels was greatly improved by increasing the homogenizing of an annealing temperature and refining processes. The results of the pilot trial showed that the average number of piercing steel tubes for Baosteel mandrels was over 3000 ,which reached the level of imported mandrels.展开更多
In this study,the microstructural evolution of H13 mandrel steel during its manufacturing process and the influence of the preheat treatment procedure and the second-step tempering temperature on its microstructural a...In this study,the microstructural evolution of H13 mandrel steel during its manufacturing process and the influence of the preheat treatment procedure and the second-step tempering temperature on its microstructural and mechanical properties were investigated.The experiment results showed that,using an H13 mandrel steel billet in the as-annealed condition produced by Baosteel as a raw material,the preheat treatments of normalization,spheroidization annealing,or normalization plus spheroidization annealing,as described in this paper,had no significant effect on the final mechanical properties after quenching and tempering.H13 mandrel steel met all the mechanical property requirements via quenching and tempering without preheat treatment.In the temperature range from 600 to 680 t,with an increase in the second-step tempering temperature,the strength gradually decreased whereas the plasticity and toughness gradually improved.Using the quenching-plus-first-tempering procedure of 1030℃/l h/oil cooling+600℃/5 h/air cooling,good balance between strength and toughness could be achieved by selecting 650℃ as the second-step tempering temperature.The test results also showed that the holding time of the second tempering played a big role in the mechanical properties.When this holding time was extended from 1 to 2 h,the hardness of the H13 mandrel steel decreased and the extent of this reduction increased with an increase in the second-step tempering temperature.In the temperature range of 1030 to 1090℃,the yield strength,tensile strength,and hardness gradually increased,however,the impact toughness decreased with increases in the quenching temperature.展开更多
The conditions of heating and cooling of piercing mandrels made of 4X5MFS steel of a three-roll screw mill 30-80 in the production of a closed cavity of steel vessels of small volume are determined.It is established t...The conditions of heating and cooling of piercing mandrels made of 4X5MFS steel of a three-roll screw mill 30-80 in the production of a closed cavity of steel vessels of small volume are determined.It is established that multiple cycles of heating up to 600℃ and cooling with water up to 80℃ for about 7 seconds/1 cycle lead to the formation of ridges,shells and cracks on the surface and in the volume of the tool.The loss of structural strength of the material leads to the breakdown of the mandrel during the stitching process.The technique and equipment of magnetic powder control have been developed to establish the dynamics of the growth of internal and external defects of mandrels.An equation is obtained that allows determining the increase in the number of defects in the sewing tool of a screw rolling mill.The technology of non-destructive testing made it possible to develop a rational plan for replacing the sewing mandrels,which allows for predicting the appearance of defects leading to a complex breakdown of the deforming tool at the NPO Pribor machine-building enterprise.展开更多
The effect of mandrel with the structure of ball and socket on the cross section quality of thin-walled tube numerical controlled(NC) bending was studied by numerical simulation method, combined with theoretical (anal...The effect of mandrel with the structure of ball and socket on the cross section quality of thin-walled tube numerical controlled(NC) bending was studied by numerical simulation method, combined with theoretical (analysis) and experiment. Influencing factors of the mandrel include the count of mandrel heads, the diameter of mandrel and its position. According to the principle of NC tube bending, quality defects possibly produced in thin-walled tube NC bending process were analyzed and two parameters were proposed in order to describe the cross section quality of thin-walled tube NC bending. According to the geometrical dimension of tube and dies, the range of mandrel protrusion was derived. The finite element model of thin-walled tube NC bending was established based on the DYNAFORM platform, and key technological problems were solved. The model was verified by experiment. The effect of the number of mandrel heads, the diameter of mandrel and the protrusion length of mandrel on the cross section quality of thin-walled tube NC bending was revealed and how to choose mandrel parameters was presented.展开更多
The aluminium tubes with high strength and smooth outer-surface can be produced by non-mandrel drawing process. It is an effective method to study forming mechanism of drawing process by simulation, based on which the...The aluminium tubes with high strength and smooth outer-surface can be produced by non-mandrel drawing process. It is an effective method to study forming mechanism of drawing process by simulation, based on which the relevant dies with reasonable dimensions can be designed to ensure tube precision. The dynamic model and elasto-plastic finite element model of the forming process were established based on FEM software Deform-3D, then the simulation was performed. The expressions about drawing load were deduced, and the influence of friction coefficient on drawing load was computed by the expressions and software respectively. Based on simulation results the deformation mechanism of drawing process without plug was expounded. According to flowing speed vector graph the law of material flowing was summarized, by which the deformation regions were partitioned. Furthermore, some potential problems of drawing process such as diameter shrinking, thickness varying were forecast and analyzed quantificationally.展开更多
文摘Based on the important boundary conditions of rolling simulation including friction, heat conduction and interactionsof the workpiece and rolls, the hot continuous rolling processes of large-diameter mandrel round bar (200 mm indiameter) in 6VH-stand hot tandem mill are successfully simulated by three-dimensional coupled thermomechanicalelastoplastic finite element method (FEM). The distributions of stress, strain, temperature and the rolling force andtorque for the two-pass and four-pass continuous rolling are calculated respectively. Thus, the two and four-passroll schedules are verified, respectively. The simulation results show that it is safe to produce 200 mm round barby the two-pass (oval pass and round pass) continuous rolling on the existing equipment compared to the four-passcontinuous rolling. There are concave surfaces and increased widths occurring at the end of rolled billet due touneven deformations between the outside and inside of the workpiece as well as the free spreading close to the rollgap of the final pass.
文摘In the process of steel tube production, continuous tube rolling is the foremost forming procedure and the critical step that decides the dimension precision and the surface quality. In the actual production of the 4140 mm full floating mandrel mill in Steel Tube Branch in Baosteel, steel T91 was chosen to be the typical sample, self-made rolling force transducer and mandrel velocity testing equipment were used, and a series of comprehensive tests on rolling parameters including the rolling force and mandrel velocity were carried out. After the experiment, the friction state between rolling tube and mandrel was analyzed. The friction coefficient was calculated and the values of 0. 033 - 0. 074 in each mill were obtained. The friction coefficient increases obviously along the rolling direction.
基金Item Sponsored by National Natural Science Foundation of China (50675187)Natural Science Foundation for Youths of Hebei Province of China (E2010001161)
文摘Roller pass is one of the key factors affecting the product quality in the retained mandrel rolling process. The metal flow condition of rolling deformation area was researched using the FEA （finite element analysis） software Marc. The influences of the pass bottom radius, the sidewall radius, the sidewall angle, the roller shoulder fillet radius, as well as the roller gap on the rolling process under the conditions of different friction were discussed. Based on these results, the changes of the workpiece exit width, the mandrel axial force, the rolling force, and the rolling torque associated with various parameters were determined, which would provide the basis for designing the pass and determining the rolling condition reasonably.
文摘Optical microscope, stereomicroscope, scanning electronic microscope （SEM） and mechanical property testing were used to research the effects of different quenching temperatures on the microstructure and mechanical properties of the H13 mandrel steel. The results indicate that following an increase in the quenching ,the degree of alloying is enhanced due to the carbides dissolving gradually in austenite, which improves the hardenability of the specimens, as well as their room and high-temperature strength. At the same time, the fracture toughness increases due to the increment of the martensite number and the interparticle distance of impact toughness. Optimal performance Consequently,the service life of the H13 the carbides. However, extremely coarse grain and martensite can decrease the can be obtained after quenching at 1 060℃ and double tempering at 620℃mandrel steel is extended significantly.
基金Project(52075272) supported by the National Natural Science Foundation of ChinaProject(LY18E050006) supported by the Natural Science Foundation of Zhejiang Province,China+1 种基金Project(2017A610088) supported by the Natural Science Foundation of Ningbo City,ChinaProjects(2018B10004, 2019B10100) supported by the Ningbo Science and Technology Plan,China。
文摘During the process of cross wedge rolling of aluminum alloy hollow shaft, the evolution of its microstructure has an important influence on the mechanical properties of the rolled piece. In order to obtain the microstructure evolution law of aluminum alloy hollow shaft in cross wedge rolling without mandrel, a finite element model is constructed through the finite element software Deform-3D. The influences of rolling temperature, sectional shrinkage,spreading angle and forming angle on the average grain size of rolled piece are studied by numerical simulation of microstructure evolution. The cellular automata method reveals the inherent relationship between the process parameters and the evolution of the microstructure, and provides a reference for optimizing the rolling process parameters of aluminum alloy hollow shafts and improving the forming quality. The results show that the average grain size of the rolled piece increases with the increase of the rolling temperature, decreases with the increase of the sectional shrinkage,and decreases first and then increases with the increase of the spreading angle, and changes little with the increase of the forming angle.
基金co-supported by the National Natural Science Foundation of China(Nos.51601070 and 51875263)the Open Project of Guangdong Key Laboratory of Precision Equipment and Manufacturing Technology,China(No.PEMT202102)the Natural Science Foundation of Jiangsu Province,China(No.BK20181447)。
文摘Two new size factors of cross-section hollow coefficient and bending degree are introduced to reveal the size effect of bending forming of bimetallic composite tube.Hollow coefficient and bending degree can limit the commonly used bent tube to the size description range of(0,2.00).The evolution laws of the cross-section distortion forms in the hollow coefficient-bending degree interval are revealed as well as the action of the mandrel-cores on the size effect.Results show the mandrel-cores filling can expand the forming limit of the bent tube,but also bring two other forming defects of wrinkle and rupture.The identification factor(hollow coefficient multiply bending degree)provides a method for querying the cross-section distortion forms of all composite bending tubes.In the identification factor interval(0,1.00),the distribution area of bending forming defects of the composite tube is continuous.The thin-walled composite bending tube collapses when identification factor in(0,0.39),wrinkles when identification factor in[0.39,0.50),and ruptures when identification factor in[0.50,1.00).The mathematical model of size effect is derived,by which the average cross-section distortion rate is found to distribute like a radial leaf in the hollow coefficient-bending degree qualified forming space.The best forming zone is hollow coefficient 0.46-0.68,and bending degree 0.25-0.47.
文摘This study researches the effects of the refining treatment on the microstructure and the mechanical properties of H13 mandrel steel and compares these effects with those of the conventional treatment. The results indicate that both carbide particles and grains were refined, carbide particles were uniformly distributed by the refining treatment, and therefore,the strength and toughness of H13 mandrel steel were improved. Rapid cooling after the solution treatment may inhibit intra-granular precipitation of carbide particles, which is favorable to enhancing toughness. Consequently, high- performance H13 mandrel steel can be produced by proper refining treatment.
文摘Based on the ABAQUS explicit dynamic simulation platform,the finite element model of single stand mill with restrained mandrel was adopted to research the influence of mandrel - roller velocity ratio (MRVR),mandrel friction and tension between stands on rolling force.The analysis results show that when the MRVR is lower than 1,the rolling force increases obviously with the increase of MRVR and reaches the peak value when the MRVR is about 1.The rolling force increase induced by the MRVR increase is the main reason of the formation of the bulge defect on the tube head and tail at the entering and exiting stage during tube continuous rolling process by full floating mandrel mill,which can be intensified by the increase of mandrel friction coefficient.The rolling force decreases with the increase of tension.As the tension is larger, the rolling force decrease amplitude is larger.The influence of backward tension on rolling force is greater than that of forward tension distinctly.Tension control can be used to decrease the rolling force increase induced by the MRVR increase,which is imposing tension at the same time when the MRVR increases,in order to improve even eliminate the bulge defect,and enhance the tube dimension precision.
文摘The microstructures and mechanical properties of H13 mandrels made by Baosteel and foreign companies were investigated in this study. Based on the comparison research, the processes were optimized, such as steelmaking, heat treatment and multiple forging processes. The quality of Baosteel mandrels was greatly improved by increasing the homogenizing of an annealing temperature and refining processes. The results of the pilot trial showed that the average number of piercing steel tubes for Baosteel mandrels was over 3000 ,which reached the level of imported mandrels.
文摘In this study,the microstructural evolution of H13 mandrel steel during its manufacturing process and the influence of the preheat treatment procedure and the second-step tempering temperature on its microstructural and mechanical properties were investigated.The experiment results showed that,using an H13 mandrel steel billet in the as-annealed condition produced by Baosteel as a raw material,the preheat treatments of normalization,spheroidization annealing,or normalization plus spheroidization annealing,as described in this paper,had no significant effect on the final mechanical properties after quenching and tempering.H13 mandrel steel met all the mechanical property requirements via quenching and tempering without preheat treatment.In the temperature range from 600 to 680 t,with an increase in the second-step tempering temperature,the strength gradually decreased whereas the plasticity and toughness gradually improved.Using the quenching-plus-first-tempering procedure of 1030℃/l h/oil cooling+600℃/5 h/air cooling,good balance between strength and toughness could be achieved by selecting 650℃ as the second-step tempering temperature.The test results also showed that the holding time of the second tempering played a big role in the mechanical properties.When this holding time was extended from 1 to 2 h,the hardness of the H13 mandrel steel decreased and the extent of this reduction increased with an increase in the second-step tempering temperature.In the temperature range of 1030 to 1090℃,the yield strength,tensile strength,and hardness gradually increased,however,the impact toughness decreased with increases in the quenching temperature.
文摘The conditions of heating and cooling of piercing mandrels made of 4X5MFS steel of a three-roll screw mill 30-80 in the production of a closed cavity of steel vessels of small volume are determined.It is established that multiple cycles of heating up to 600℃ and cooling with water up to 80℃ for about 7 seconds/1 cycle lead to the formation of ridges,shells and cracks on the surface and in the volume of the tool.The loss of structural strength of the material leads to the breakdown of the mandrel during the stitching process.The technique and equipment of magnetic powder control have been developed to establish the dynamics of the growth of internal and external defects of mandrels.An equation is obtained that allows determining the increase in the number of defects in the sewing tool of a screw rolling mill.The technology of non-destructive testing made it possible to develop a rational plan for replacing the sewing mandrels,which allows for predicting the appearance of defects leading to a complex breakdown of the deforming tool at the NPO Pribor machine-building enterprise.
文摘The effect of mandrel with the structure of ball and socket on the cross section quality of thin-walled tube numerical controlled(NC) bending was studied by numerical simulation method, combined with theoretical (analysis) and experiment. Influencing factors of the mandrel include the count of mandrel heads, the diameter of mandrel and its position. According to the principle of NC tube bending, quality defects possibly produced in thin-walled tube NC bending process were analyzed and two parameters were proposed in order to describe the cross section quality of thin-walled tube NC bending. According to the geometrical dimension of tube and dies, the range of mandrel protrusion was derived. The finite element model of thin-walled tube NC bending was established based on the DYNAFORM platform, and key technological problems were solved. The model was verified by experiment. The effect of the number of mandrel heads, the diameter of mandrel and the protrusion length of mandrel on the cross section quality of thin-walled tube NC bending was revealed and how to choose mandrel parameters was presented.
基金Project(2005AA3012-4) supported by Science and Technology Committee of Chongqing, China
文摘The aluminium tubes with high strength and smooth outer-surface can be produced by non-mandrel drawing process. It is an effective method to study forming mechanism of drawing process by simulation, based on which the relevant dies with reasonable dimensions can be designed to ensure tube precision. The dynamic model and elasto-plastic finite element model of the forming process were established based on FEM software Deform-3D, then the simulation was performed. The expressions about drawing load were deduced, and the influence of friction coefficient on drawing load was computed by the expressions and software respectively. Based on simulation results the deformation mechanism of drawing process without plug was expounded. According to flowing speed vector graph the law of material flowing was summarized, by which the deformation regions were partitioned. Furthermore, some potential problems of drawing process such as diameter shrinking, thickness varying were forecast and analyzed quantificationally.
