大锻件材料30Cr2Ni4MoV钢的热变形特性研究
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摘要
大锻件通常用来制造大型结构件和重要承载零部件。随着电力、钢铁、石化、国防等行业的发展,大锻件的需求量越来越大。最近十年,我国大锻件的需求量将持续在一个高点,其中大型电站设备又将是需求的主要市场。但是,由于我国工业起步较晚,大锻件的制造能力难以达到要求,因而许多大锻件需要从国外进口,这不仅加重了各行业的负担,还使我国难以掌握关键性技术,限制了行业的发展。所以如何提高大锻件的生产能力将是我国面临的一个难题。
大锻件的生产采用热加工,以便降低加工载荷。大锻件成本极高,一般不允许锻造失败,因此,研究大锻件材料热变形特性(流动应力和微观组织演变规律),将所建立的模型运用于计算机模拟,可以代替部分大型锻造试验,是研究大锻件成形规律、实现“控形控性”目标的最有力手段之一。
本文选取我国生产低压转子的大锻件材料30Cr2Ni4MoV钢作为研究对象,通过热模拟压缩试验和定量金相试验获得大量的数据,从而建立了该种材料的高温流动应力模型和微观组织演变模型。
通过将30Cr2Ni4MoV试样在Gleeble-3500热模拟机上进行热压缩试验,得到其真应力-应变的试验数据。30Cr2Ni4MoV钢在高温下的流动应力曲线具有典型的动态再结晶特征。针对流动应力随变形而变化的两个阶段,将材料的流动应力曲线分成加工硬化-动态回复阶段和动态再结晶阶段。建立模型时,认为变形温度决定了原子的扩散能力和位错移动的驱动力,变形速率决定了位错密度和晶界能的积累速度,借助Zener-Hollomon参数建立了各个特征变量的数学表达式,确立了该种材料的高温流动应力模型。并通过对动态再结晶阶段的流动应力分析,确立了该种材料的动态再结晶动力学模型。
通过对试样进行定量金相分析,测量出30Cr2Ni4MoV试样在不同变形条件下的动态再结晶晶粒尺寸。认为动态再结晶晶粒尺寸只取决于变形条件,而与原始晶粒大小无关,借助Zener-Hollomon参数,建立了30Cr2Ni4MoV钢的动态再结晶晶粒尺寸模型。
通过对有限元软件MSC.Marc进行二次开发,将建立的流动应力模型和微观组织演变模型编写进热-力耦合程序,对30Cr2Ni4MoV钢热变形时应变、应变速率、应力、动态再结晶百分数以及动态再结晶晶粒尺寸的分布进行了数值模拟,并与实验数据对照,验证了本文建立模型的正确性。
Heavy forgings are always used to produce large-sized structural parts and significant load bearing parts. With the development of industry, such as electric power and military defense, heavy forgings are demanded especially.
In China, the gap of heavy forgings between demand and supply will be tremendous in the next decade. Particularly, China requires a large number of power plant equipments such as rotors. However, due to the low level of manufacturing industry, we have to import lots of important parts, which increase the burden of our country. More seriously, we don’t master the key technology of the heavy forgings production. Thus, we should improve the ability of heavy forgings manufacture.
Heavy forgings are difficult to process because of their large sizes and heavy weights. In order to reduce the load, they are always produced by hot processing. Because of their high costs, heavy forgings are not allowed to fail. Therefore, we should find out their high temperature deformation characteristics, which contain the flow stress behavior and microstructure evolution to simulate the large forgings’deformation by computers afterwards.
Based on the Gleeble-3500 thermo-mechanical simulation tests of alloy steel 30Cr2Ni4MoV, which is the material of low pressure rotor, a model of flow stress characterized by dynamic recrystallization (DRX) for 30Cr2Ni4MoV was put forward. In the model, the high temperature flow stress curve was divided into dynamic recovery region and dynamic recrystallization region. The characteristic parameters of flow stress models were described as functions of Zener-Hollomon parameter. By analyzing the dynamic recrystallization region of flow stress curve, the Kinetics of dynamic recrystallization was modeled.
Based on the metallographic experiment, the dynamic recrystallization grain size of every specimen was measured. The model of dynamic recrystallization grain size was put forward on the basis of idea that the grain size is only determined by the deformation condition, which can be expressed by the Zener-Hollomon parameter Z.
Based on MSC.Marc, a numerical simulation system for analyzing deformation and microstructural evolution was developed. Making using of the developed system, the distributions of equivalent strain, equivalent strain rate, equivalent stress, dynamic recrystallization volume fraction and dynamic recrystallization grain size in the specimen were obtained. The simulation results agree with the experimental results, which show the models and numerical simulation system can be used to design and optimize heavy forging processing techniques.
大锻件的生产采用热加工,以便降低加工载荷。大锻件成本极高,一般不允许锻造失败,因此,研究大锻件材料热变形特性(流动应力和微观组织演变规律),将所建立的模型运用于计算机模拟,可以代替部分大型锻造试验,是研究大锻件成形规律、实现“控形控性”目标的最有力手段之一。
本文选取我国生产低压转子的大锻件材料30Cr2Ni4MoV钢作为研究对象,通过热模拟压缩试验和定量金相试验获得大量的数据,从而建立了该种材料的高温流动应力模型和微观组织演变模型。
通过将30Cr2Ni4MoV试样在Gleeble-3500热模拟机上进行热压缩试验,得到其真应力-应变的试验数据。30Cr2Ni4MoV钢在高温下的流动应力曲线具有典型的动态再结晶特征。针对流动应力随变形而变化的两个阶段,将材料的流动应力曲线分成加工硬化-动态回复阶段和动态再结晶阶段。建立模型时,认为变形温度决定了原子的扩散能力和位错移动的驱动力,变形速率决定了位错密度和晶界能的积累速度,借助Zener-Hollomon参数建立了各个特征变量的数学表达式,确立了该种材料的高温流动应力模型。并通过对动态再结晶阶段的流动应力分析,确立了该种材料的动态再结晶动力学模型。
通过对试样进行定量金相分析,测量出30Cr2Ni4MoV试样在不同变形条件下的动态再结晶晶粒尺寸。认为动态再结晶晶粒尺寸只取决于变形条件,而与原始晶粒大小无关,借助Zener-Hollomon参数,建立了30Cr2Ni4MoV钢的动态再结晶晶粒尺寸模型。
通过对有限元软件MSC.Marc进行二次开发,将建立的流动应力模型和微观组织演变模型编写进热-力耦合程序,对30Cr2Ni4MoV钢热变形时应变、应变速率、应力、动态再结晶百分数以及动态再结晶晶粒尺寸的分布进行了数值模拟,并与实验数据对照,验证了本文建立模型的正确性。
Heavy forgings are always used to produce large-sized structural parts and significant load bearing parts. With the development of industry, such as electric power and military defense, heavy forgings are demanded especially.
In China, the gap of heavy forgings between demand and supply will be tremendous in the next decade. Particularly, China requires a large number of power plant equipments such as rotors. However, due to the low level of manufacturing industry, we have to import lots of important parts, which increase the burden of our country. More seriously, we don’t master the key technology of the heavy forgings production. Thus, we should improve the ability of heavy forgings manufacture.
Heavy forgings are difficult to process because of their large sizes and heavy weights. In order to reduce the load, they are always produced by hot processing. Because of their high costs, heavy forgings are not allowed to fail. Therefore, we should find out their high temperature deformation characteristics, which contain the flow stress behavior and microstructure evolution to simulate the large forgings’deformation by computers afterwards.
Based on the Gleeble-3500 thermo-mechanical simulation tests of alloy steel 30Cr2Ni4MoV, which is the material of low pressure rotor, a model of flow stress characterized by dynamic recrystallization (DRX) for 30Cr2Ni4MoV was put forward. In the model, the high temperature flow stress curve was divided into dynamic recovery region and dynamic recrystallization region. The characteristic parameters of flow stress models were described as functions of Zener-Hollomon parameter. By analyzing the dynamic recrystallization region of flow stress curve, the Kinetics of dynamic recrystallization was modeled.
Based on the metallographic experiment, the dynamic recrystallization grain size of every specimen was measured. The model of dynamic recrystallization grain size was put forward on the basis of idea that the grain size is only determined by the deformation condition, which can be expressed by the Zener-Hollomon parameter Z.
Based on MSC.Marc, a numerical simulation system for analyzing deformation and microstructural evolution was developed. Making using of the developed system, the distributions of equivalent strain, equivalent strain rate, equivalent stress, dynamic recrystallization volume fraction and dynamic recrystallization grain size in the specimen were obtained. The simulation results agree with the experimental results, which show the models and numerical simulation system can be used to design and optimize heavy forging processing techniques.
引文
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