控制Cr5钢冷轧辊坯质量的锻造变形工艺研究
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摘要
本文针对Cr5钢电渣锭锻前组织中存在的液析碳化物、孔隙性缺陷、成分偏析以及网状碳化物等一系列冶金缺陷的改善或消除问题,在与实验、实践相结合的基础上,应用数值模拟技术,对控制辊坯质量的锻造变形工艺进行了综合研究。通过建立相应的模型,展开了一系列的计算分析,从而揭示出锻造工艺参数对辊坯质量的影响实质及影响规律,为制定提高辊坯质量的锻造工艺提供了理论基础和设计方法,具有重要的实际意义。
对电解法萃取的碳化物进行XRD物相分析的结果表明,Cr5钢电渣锭中的液析碳化物以M7C3型为主。电渣锭及锻后成品Cr5钢中液析碳化物的形态及数量随保温时间变化的统计结果表明,液析碳化物在成品Cr5钢中的扩散难于电渣锭。因此,应尽可能通过锻前高温扩散处理来减少或消除液析碳化物这种缺陷。
Cr5钢电渣锭中存在一定量的孔隙性缺陷,且心部的数量多于边部,其截面形状以圆形为主。基于此,本文采用DEFORM软件模拟了Cr5钢电渣锭内部孔隙性缺陷的闭合过程,讨论不同工艺参数对孔洞压实效果的影响；据此进一步探索孔隙性缺陷闭合的本质。通过采用X射线衍射测定γ残相残余应变的方法,来获得描述应变场分布规律的解析函数。由此得出单工步锻造变形过程中,无孔模型沿压下方向的应变εz可由Gaussian函数拟合给出；有孔模型εz的分布则采用间断的Gaussian函数拟合给出,间断函数的截止限通过等面积法得到。在此基础上,从应变函数的角度提出了一种求解孔洞闭合问题的新的研究方法。通过应变函数的数学逻辑推导,得到了孔洞的临界闭合条件,给出了孔洞闭合过程规律性的本质描述。对于Cr5钢而言,提出了一种评判其内部Φ2 mm球形孔洞闭合的准则：εz0(z1)≥>0.65。实际生产工艺中,采用该闭合准则所确定的锻合区域来表达Cr5钢内部任意位置处孔洞的闭合,实现了有孔模型的简化。同时,锻合区域的给出,也将某一个或几个位置孔洞闭合情况的具体问题的研究,转化为孔洞闭合的一般性问题的研究。这就为针对性地消除锻坯内部的孔洞缺陷,提供了一条具有广泛应用前景的新途径。
多工步锻造变形过程中,应变沿轴向的分布可以由多个Gaussian函数线性叠加表达。通过应变函数的解析求解得出保证Cr5钢锭料中心锻透条件下且变形均匀的最佳送进量175.309 mm,以达到坯料心部孔洞均匀压实的目的。
退火态Cr5钢电渣锭的基体以珠光体类组织为主。在晶粒内部存在成分偏析。为此,本文分别对锻后高温扩散及未变形而直接高温扩散的Cr5钢电渣锭中Cr元素的分布进行了测试,在此基础上,从菲克第一定律的分析和讨论对其机理展开了研究。通过建立不同变形条件下的扩散模型,采用解析求解与数值求解联合求解的方法,分别从几何形状变化和锻后再结晶晶界两个方面计算了变形前、后Cr原子扩散的定量差别。结果表明,变形对扩散的影响为几何形状变化及扩散系数增大对扩散影响作用的线性叠加,为锻后Cr原子扩散加快的实验事实提供了定量的理论解释。另外,还给出了Cr原子平均扩散浓度△p1与压下率之间关系的经验公式,这对于锻造生产工艺的制定具有重要的指导意义。
为避免产生过烧现象,实际生产过程中Cr5钢的始锻温度不宜超过1200℃,据此设定Cr5钢的始锻温度为1150℃。通过对电渣锭锻造变形过程温度场的有限元模拟,给出了钢锭断面的温度场分布；并采用点跟踪的方式,分析钢锭表面及心部在锻造变形过程中温度的变化情况,解决了实际生产中无法测定钢锭内部温度变化情况的困难。另一方面,终锻温度下钢锭断面的温度场分布为锻后冷却过程的温度场计算提供了初始条件。该模拟结果表明：变形结束后,钢锭表面的温度降为900℃,而心部的温度则基本保持在1150℃。在此基础上,得出辊坯断面不同位置在冷却过程中冷却速度的变化,将其与该温度下抑制网状碳化物析出的临界冷却速度相比较,实现了对辊坯内网状碳化物分布状况的预测。在当前的冷却条件下(即环境温度为55℃的情况),距离辊身直径为Φ460 mm的辊坯外表面约30 mm厚度的尺度范围内不会出现明显的网状碳化物。
According to elimination of a series of metallurgical defects in Cr5 electroslag remelt (ESR) ingot, such as liquation carbide, void defects, composition segregation and network carbide etc, a comprehensive research on forging process controlling the quality of cold roll blank, which is based on experiments, practice and simulation technology, is carried out in this paper. By establishing the corresponding model, performing calculation and analysis, the essential features of effect of forging parameters on the quality are disclosed. It provides the theoretical basis and design method for making forging process to improve roll blank quality, which is of important practical value.
The carbide is extracted by electrolysis process and analyzed by XRD. The results show that liquation carbide is mainly M7C3 in Cr5 ESR ingot. Also, the morphology and quantity of liquation carbide changing with the holding time are counted. It shows that the diffusion of liquation carbide in Cr5 finished steel is more slowly than that in the ESR ingot. Therefore, liquation carbide, this kind of metallurgical defect, should be removed during the homogenization treatment before forging as much as possible.
There are some void defects in Cr5 ESR ingot, and voids section shape is mainly roundness. However, any internal void from the initial cast ingot needs to be eliminated. On this basis, simulation software (DEFORM-3D) is used for the analysis of the evolution of void defects in Cr5 ESR ingot during the forging operation, and the effects of parameters on void closure are discussed. Then, the essence of void closure is further explored on the basis of simulated results. Limited by conditions of high temperature and high pressure, the x-ray diffraction method for determining residual strain of retained austenite is adopted to obtain the distributions of strain in the ingot. It shows that during single-pass forging, for models without void, distribution ofεz along the vertical direction can be given by Gaussian function fitting; for models with void, while distribution ofεz can be given by discontinuous Gaussian function fitting, cutoff bound of the discontinuous function is determined by equal-area method. Hereby, a kind of new researching method for solving void closure is proposed from the view of strain function. Then, the critical condition of void closure is presented by derivation and calculation of the strain function, which gives the essential description of void closing. For Cr5 steel, the criterion for spherical void closure is proposed, i.e.,εz0(z1)≥0.65. In the practical process, the region of void closure determined by the criterion is developed to express the closure of void located at any position, which simplifies the models with void. Also, with the region of void closure, a specific problem of the closing of void located at one or other position is transformed into a general one. It provides a new approach with extensive application prospect in terms of elimination of void defects in the ingot.
During multiple-pass forging, the distributions of strain in the axial forging zones can be expressed by linearly superposition of the Gaussian functions. The optimal value of feed, i.e., x0=175.309 mm, which can assure uniform strain distributions in the center of forgings, is determined by analytic solution of the strain function. Hereby, an efficient forging process is presented to improve the void closing and to achieve the uniform forging effect.
Pearlite is the dominant microstructure in the matrix of annealed Cr5 ESR ingot. And there is composition segregation inside the grains. Therefore, distribution of chromium in Cr5 ESR ingot under two different states (i.e., the homogenization treatment after forging and the homogenization treatment with no deformation) is measured in the present paper. On the basis of the experimental data, the mechanism is studied from the view of the Fick's first law. By establishing the diffusion model with different deformation conditions, using combined solution of the analytic and numerical solution, the quantitative differences of diffusivity of Cr pre and post deformation are calculated from the two aspects, the geometry change and recrystallization grain boundary. It shows effect of forging on diffusion is made of linear superposition of effect of the geometry change and recrystallization grain boundary, which proposes quantitative and theoretical explanation of forging enhancing the diffusion. In addition, an empirical formula to describe the relationship between the average diffusion concentration of Cr and the relative draft is presented, which has guiding significance for making the forging process.
In order to avoid overburning, the initial forging temperature of Cr5 steel should not exceed 1200℃, hereby, it is set at 1150℃. The temperature field distribution of cross section is given by numerical simulation of temperature field of the ESR ingot forging process; by the mode of point tracking, the temperature variation on the surface and inner of the ingot are analyzed, and the difficulties that the temperature variation on the inner of the ingot can't be measured in the practical process are solved. On the other hand, the temperature field distribution of cross section at the final forging temperature provides initial conditions for calculating the temperature field of cooling after forging. The simulation results show that ingot surface temperature is decreased to 900℃, and the temperature at the core almost remains in 1150℃after forging. On this basis, the variation of cooling rate in different site of cross section is obtained. By comparing with the critical cooling rate restraining network carbide precipitation at that temperature, prediction for the distributions of network carbide is implemented. At current cooling conditions(i.e., with the environmental temperature of 55℃), there is no obvious network carbide precipitation within about 30 mm scale range apart from the surface of roll blank with the roll diameter 460 mm.
对电解法萃取的碳化物进行XRD物相分析的结果表明,Cr5钢电渣锭中的液析碳化物以M7C3型为主。电渣锭及锻后成品Cr5钢中液析碳化物的形态及数量随保温时间变化的统计结果表明,液析碳化物在成品Cr5钢中的扩散难于电渣锭。因此,应尽可能通过锻前高温扩散处理来减少或消除液析碳化物这种缺陷。
Cr5钢电渣锭中存在一定量的孔隙性缺陷,且心部的数量多于边部,其截面形状以圆形为主。基于此,本文采用DEFORM软件模拟了Cr5钢电渣锭内部孔隙性缺陷的闭合过程,讨论不同工艺参数对孔洞压实效果的影响；据此进一步探索孔隙性缺陷闭合的本质。通过采用X射线衍射测定γ残相残余应变的方法,来获得描述应变场分布规律的解析函数。由此得出单工步锻造变形过程中,无孔模型沿压下方向的应变εz可由Gaussian函数拟合给出；有孔模型εz的分布则采用间断的Gaussian函数拟合给出,间断函数的截止限通过等面积法得到。在此基础上,从应变函数的角度提出了一种求解孔洞闭合问题的新的研究方法。通过应变函数的数学逻辑推导,得到了孔洞的临界闭合条件,给出了孔洞闭合过程规律性的本质描述。对于Cr5钢而言,提出了一种评判其内部Φ2 mm球形孔洞闭合的准则：εz0(z1)≥>0.65。实际生产工艺中,采用该闭合准则所确定的锻合区域来表达Cr5钢内部任意位置处孔洞的闭合,实现了有孔模型的简化。同时,锻合区域的给出,也将某一个或几个位置孔洞闭合情况的具体问题的研究,转化为孔洞闭合的一般性问题的研究。这就为针对性地消除锻坯内部的孔洞缺陷,提供了一条具有广泛应用前景的新途径。
多工步锻造变形过程中,应变沿轴向的分布可以由多个Gaussian函数线性叠加表达。通过应变函数的解析求解得出保证Cr5钢锭料中心锻透条件下且变形均匀的最佳送进量175.309 mm,以达到坯料心部孔洞均匀压实的目的。
退火态Cr5钢电渣锭的基体以珠光体类组织为主。在晶粒内部存在成分偏析。为此,本文分别对锻后高温扩散及未变形而直接高温扩散的Cr5钢电渣锭中Cr元素的分布进行了测试,在此基础上,从菲克第一定律的分析和讨论对其机理展开了研究。通过建立不同变形条件下的扩散模型,采用解析求解与数值求解联合求解的方法,分别从几何形状变化和锻后再结晶晶界两个方面计算了变形前、后Cr原子扩散的定量差别。结果表明,变形对扩散的影响为几何形状变化及扩散系数增大对扩散影响作用的线性叠加,为锻后Cr原子扩散加快的实验事实提供了定量的理论解释。另外,还给出了Cr原子平均扩散浓度△p1与压下率之间关系的经验公式,这对于锻造生产工艺的制定具有重要的指导意义。
为避免产生过烧现象,实际生产过程中Cr5钢的始锻温度不宜超过1200℃,据此设定Cr5钢的始锻温度为1150℃。通过对电渣锭锻造变形过程温度场的有限元模拟,给出了钢锭断面的温度场分布；并采用点跟踪的方式,分析钢锭表面及心部在锻造变形过程中温度的变化情况,解决了实际生产中无法测定钢锭内部温度变化情况的困难。另一方面,终锻温度下钢锭断面的温度场分布为锻后冷却过程的温度场计算提供了初始条件。该模拟结果表明：变形结束后,钢锭表面的温度降为900℃,而心部的温度则基本保持在1150℃。在此基础上,得出辊坯断面不同位置在冷却过程中冷却速度的变化,将其与该温度下抑制网状碳化物析出的临界冷却速度相比较,实现了对辊坯内网状碳化物分布状况的预测。在当前的冷却条件下(即环境温度为55℃的情况),距离辊身直径为Φ460 mm的辊坯外表面约30 mm厚度的尺度范围内不会出现明显的网状碳化物。
According to elimination of a series of metallurgical defects in Cr5 electroslag remelt (ESR) ingot, such as liquation carbide, void defects, composition segregation and network carbide etc, a comprehensive research on forging process controlling the quality of cold roll blank, which is based on experiments, practice and simulation technology, is carried out in this paper. By establishing the corresponding model, performing calculation and analysis, the essential features of effect of forging parameters on the quality are disclosed. It provides the theoretical basis and design method for making forging process to improve roll blank quality, which is of important practical value.
The carbide is extracted by electrolysis process and analyzed by XRD. The results show that liquation carbide is mainly M7C3 in Cr5 ESR ingot. Also, the morphology and quantity of liquation carbide changing with the holding time are counted. It shows that the diffusion of liquation carbide in Cr5 finished steel is more slowly than that in the ESR ingot. Therefore, liquation carbide, this kind of metallurgical defect, should be removed during the homogenization treatment before forging as much as possible.
There are some void defects in Cr5 ESR ingot, and voids section shape is mainly roundness. However, any internal void from the initial cast ingot needs to be eliminated. On this basis, simulation software (DEFORM-3D) is used for the analysis of the evolution of void defects in Cr5 ESR ingot during the forging operation, and the effects of parameters on void closure are discussed. Then, the essence of void closure is further explored on the basis of simulated results. Limited by conditions of high temperature and high pressure, the x-ray diffraction method for determining residual strain of retained austenite is adopted to obtain the distributions of strain in the ingot. It shows that during single-pass forging, for models without void, distribution ofεz along the vertical direction can be given by Gaussian function fitting; for models with void, while distribution ofεz can be given by discontinuous Gaussian function fitting, cutoff bound of the discontinuous function is determined by equal-area method. Hereby, a kind of new researching method for solving void closure is proposed from the view of strain function. Then, the critical condition of void closure is presented by derivation and calculation of the strain function, which gives the essential description of void closing. For Cr5 steel, the criterion for spherical void closure is proposed, i.e.,εz0(z1)≥0.65. In the practical process, the region of void closure determined by the criterion is developed to express the closure of void located at any position, which simplifies the models with void. Also, with the region of void closure, a specific problem of the closing of void located at one or other position is transformed into a general one. It provides a new approach with extensive application prospect in terms of elimination of void defects in the ingot.
During multiple-pass forging, the distributions of strain in the axial forging zones can be expressed by linearly superposition of the Gaussian functions. The optimal value of feed, i.e., x0=175.309 mm, which can assure uniform strain distributions in the center of forgings, is determined by analytic solution of the strain function. Hereby, an efficient forging process is presented to improve the void closing and to achieve the uniform forging effect.
Pearlite is the dominant microstructure in the matrix of annealed Cr5 ESR ingot. And there is composition segregation inside the grains. Therefore, distribution of chromium in Cr5 ESR ingot under two different states (i.e., the homogenization treatment after forging and the homogenization treatment with no deformation) is measured in the present paper. On the basis of the experimental data, the mechanism is studied from the view of the Fick's first law. By establishing the diffusion model with different deformation conditions, using combined solution of the analytic and numerical solution, the quantitative differences of diffusivity of Cr pre and post deformation are calculated from the two aspects, the geometry change and recrystallization grain boundary. It shows effect of forging on diffusion is made of linear superposition of effect of the geometry change and recrystallization grain boundary, which proposes quantitative and theoretical explanation of forging enhancing the diffusion. In addition, an empirical formula to describe the relationship between the average diffusion concentration of Cr and the relative draft is presented, which has guiding significance for making the forging process.
In order to avoid overburning, the initial forging temperature of Cr5 steel should not exceed 1200℃, hereby, it is set at 1150℃. The temperature field distribution of cross section is given by numerical simulation of temperature field of the ESR ingot forging process; by the mode of point tracking, the temperature variation on the surface and inner of the ingot are analyzed, and the difficulties that the temperature variation on the inner of the ingot can't be measured in the practical process are solved. On the other hand, the temperature field distribution of cross section at the final forging temperature provides initial conditions for calculating the temperature field of cooling after forging. The simulation results show that ingot surface temperature is decreased to 900℃, and the temperature at the core almost remains in 1150℃after forging. On this basis, the variation of cooling rate in different site of cross section is obtained. By comparing with the critical cooling rate restraining network carbide precipitation at that temperature, prediction for the distributions of network carbide is implemented. At current cooling conditions(i.e., with the environmental temperature of 55℃), there is no obvious network carbide precipitation within about 30 mm scale range apart from the surface of roll blank with the roll diameter 460 mm.
引文
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