双辊铸轧不锈钢薄带开裂分析与温度场和应力场的数值模拟
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摘要
本文从实际双辊铸轧生产的304不锈钢薄带上取样，采用金相、SEM等对裂纹形貌进行观察，采用金相和XRD等对其组织和相结构进行分析，并对304不锈钢进行DSC测定，确认其在室温下的相组成。研究其凝固过程中的析出相问题。采用热模拟试验机，测定不锈钢在不同温度下的应力－应变曲线，并测定其膨胀系数。
采用304不锈钢圆柱试样分别进行快冷和缓冷处理，测量沿半径方向的残余应力，建立有限元模型对其温度场和应力场进行数值模拟，通过调整参数，证明其模型的正确性。
应用有限元法建立熔池内钢液流动和传热的耦合模型，利用此模型模拟双辊铸轧薄带钢凝固过程中的温度场和流场，同时，对双辊铸轧过程中304不锈钢薄带在出口的温度进行了测量，采用此模型，模拟了各种工艺参数对熔液凝固过程的影响，探索适宜的工艺参数值。应用有限元法建立双辊铸轧薄带钢应力场的计算模型，结合流热耦合所获得的温度场，模拟双辊铸轧薄带钢的应力场，分析各种影响因素。通过铸轧薄带钢内的应力分布，研究薄带表面裂纹随工艺参数变化产生的可能性。通过应力场模拟结果，探讨铸轧薄带钢过程中裂纹的形成机理。
双辊铸轧薄带开裂分析表明，铸轧薄带上的裂纹在表面凹痕处产生，并沿柱状晶晶间向内部扩展，且在裂纹附近柱状晶和等轴晶交界处存大量缩孔。铸轧断口表面存在大量氧化物，说明铸轧裂纹在高温时即已产生。通过观察在不同温度下304不锈钢铸轧薄带的金相组织和对室温下304不锈钢的XRD分析，并结合DSC曲线和相图，说明304不锈钢存在高温相变δ→γ。随着温度的升高，304不锈钢抵抗变形的能力减弱，塑性逐渐变好。
对304不锈钢圆柱试样淬火和空冷两种状态下残余应力场进行测量和数值模拟，结果表明，二者吻合较好，证明了所建模型的有效性。采用这一模型对不同时间和不同位置的温度场和应力场进行了数值模拟。淬火试样在开始冷却时，其表面表现出切向拉应力，中部表现为切向压应力。随着冷却时间的延长行，试样应力逐渐减小，最终减少至零。随后，其表面转变为切向压应力，中心转变为切向拉应力。在此过程中，试样的应力逐渐增大。当冷却时间为90s时，试样的应力表现为残余应力。空冷试样在开始冷却时表面表现为切向拉应力，心部表现为切向压应力。随着冷却时间的延长，试样的拉应力和压应力均逐渐减小。当试样冷却至1800s时，其表面和心部的应力值非常小，均接近于零，此时的应力为残余应力。
对双辊铸轧不锈钢薄带在一定铸轧参数下出口温度的实验测量结果与有限元数值模拟结果进行对比发现，二者的吻合性较好，证明了所建模型的有效性。利用所建模型，对不同铸轧参数下的温度场和流场进行了模拟。铸轧速度越大，铸轧薄带出口温度越高，钢液凝固点的位置越低；浇注温度越高，熔池的整体温度和薄带的出口温度均升高，钢液凝固点的位置越低；辊径越大，熔池的整体温度下降，钢液凝固点的位置升高；薄带越厚，熔池内整体温度升高，凝固点的位置下降。
利用流热耦合数值模拟所获得的温度场，模拟了铸轧薄带出口以上和铸轧薄带出口以下的应力场。铸轧薄带出口以上的应力场模拟结果表明，最大拉应力出现在薄带与铸轧辊的接触面靠近出口的位置；最大压应力出现在薄带中心靠近出口的位置。模拟了各种工艺参数对铸轧薄带出口以上应力场的影响。随着铸轧速度的增大，沿接触面的整体应力减小，出口整体拉应力值和压应力值均减小，薄带表面和中心的应力差减小；随着浇注温度的升高，接触面上的整体应力减小，但出口的应力分布曲线接近重合，说明浇注温度对出口处的应力影响很小；随着辊径的增大，沿接触面的整体应力增加，但出口的应力分布曲线接近重合，说明辊径变化对出口处的应力影响很小；随着带厚的增加，最大应力出现位置的弧度降低，沿出口厚度方向整体应力值均增大。
铸轧薄带出口以下的应力场模拟结果表明，薄带冷却初期，薄带的心部温度高于表面温度。随着冷却时间的延长，试样心部和表面温度均降低，薄带的中心与表面温差越来越小。此外，在冷却过程中，试样表面在长度方向的应力表现为拉应力，心部表现为为压应力。当冷却时间延长时，表面拉应力逐渐减小，最终减小至零；随后，其应力状态转变为压应力，中心压应力减小至零随后转变为拉应力，并且应力值逐渐增大。
The specimen was taken from the strip of the304stainless steel after twin-roll stripcasting. The microstructure and fractograph of the specimen was observed by OM andSEM. The phase structure of the specimen were deterimined by XRD. Meanwhile, the DSCcurve of304stainless steel during the cooling process was measured. The stress-straincurves of304stainless steel at different temperatures were measured by thermo-simulatingmachine and its dilatometric curve was determined too.
The residual stress fields of the column specimens after quenching and air coolingwere measured, and the FEM of them was built and the stress fields were simulated. Thesimulated results were compared with the measured one.
The FEM of the coupling fields between the temperature and fluid during the stripcasting of304stainless steel was built in this work. By using this model, the temperatureand fluid fields during the strip casting of304stainless steel were simulated. Meanwhile,the temperature of the304stainless steel strip at the exit during twin-roll strip castingprecess was measured. By using this model, the effect of the different technologyparameters on the solidification of the stainless steel was simulated too. Based on abovementioned model, combining simulated temperature field of the304stainless steel strip, thestress field of the304stainless steel strip was simulated too and the effect of differenttechnology parameters on the stress field was discussed in this work.
The crack analysis of the304stainless steel strip during twin-roll strip casting processshows that, the cracks occur at the dent of the strip surface and develop along the dendriticgrain boundary. The large numbers of oxides can been found on the fractograph, whichindicates that the cracks have been appeared at higher temperature. By means of themicrostructure of304stainless steel at different temperatures, the analysis of XRD result,DSC curve and the Fe-C phase diagram, the phase transformation at high temperature fromδ to γ has been carried out. With the increasing of the temperature, the strength of thestainless steel is decreased, while, the plasticity is increased.
The measured residual stresses of the column specimens after quenching and aircooling were compared with the simulated ones and they are closer to each other, whichproves the validity of this model. By using this model, the temperature and fluid fields atdifferent times and at different location of the specimen were simulated. The simulated results show that, for quenching specimen, at the beginning of the cooling process, thetangential tensile stress appears on the surface, while, tangential compress one at the center.With the increasing of the time, the stress is changed to zero, then, the tangential compressstress is appeared on the surface, while, tangential tensile one at the center, and the stress ischanged greatly. When the time is90s, the stress is the residual one. For the air coolingspecimen, at the begining of the cooling process, the tangential tensile stress is appeared onthe surface, while, tangential compress one at the center. With the increasing of the time,both of the stresses on the surface and center are decreased. When the time is1800s, thoseare very small, which are close to zero, and can be taken as residual one.
The measured temperature of the304stainless steel strip at the exit during twin-rollcasting process was compared with the simulated one, and they are closer to each other,which proves the validity of this model. By using this model, the effect of differenttechnology parameters on the temperature field was simulated. The results show that, thefaster the casting speed is, the higher the temperature of the strip at the exit and the lowerthe position of the freezing point are. Meanwhile, the higher the casting temperature is, thehigher the temperatures of the whole melting pool and the exit of the strip, and the lowerthe position of the freezing point are. Moreover, the larger the radius of the roller is, thelower the temperatures of the whole melting pool and the higher the position of the freezingpoint are. In addition, the thicker the strip is, the higher the temperatures of the wholemelting pool and the lower the position of the freezing point are.
Based on the temperature field simulated by the coupling ones during the twin-rollstrip casting of304stainless steel, the stress fields both upper and under the exit of the stripwere simulated. The simulated result of the stress field upper the exit of the strip shows that,the largest tensile stress is appeared on the contact interface between strip and the roller,which is near the exit, while, the largest compress stress is appeared at the location of thestrip center. The effect of different technology parameters on the stress field upper the exitof the strip was simulated. The faster the casting speed is, the lower the stress along thecontact interface and the lower both the tensile and compress stresses at the exit of the stripare. Meanwhile, the higher the casting temperature is, the lower the stress along the contactinterface is, however, little effect can be found at the exit of the strip. Moreover, the largerthe radius of the roller is, the higher the stress along the contact interface is, however, littleeffect can be found at the exit of the strip. In addition, the thicker the strip is, the lower thelocation of the roller radian is, at which the largest stress is appeared and the higher the stress along the direction of the strip thickness is.
The simulated result of the temperature and stress fields under the exit of the stripshows that, for the temperature field, at the beginning of the cooling process, thetemperature at the strip center is higher than that on strip surface. With the increasing of thecooling time, the temperatures at both strip center and surface are decreassed. For the stressfield, at the beginning of the cooling process, the tensile stress is appeared on the stripsurface, while, the compress one at the center.. With the increasing of the cooling time, thetensile stress on the strip surface is decreased into zero, then increased into compress stress,however, the compress stress at the strip center is decreased into zero, then increased intotensile stress.
采用304不锈钢圆柱试样分别进行快冷和缓冷处理，测量沿半径方向的残余应力，建立有限元模型对其温度场和应力场进行数值模拟，通过调整参数，证明其模型的正确性。
应用有限元法建立熔池内钢液流动和传热的耦合模型，利用此模型模拟双辊铸轧薄带钢凝固过程中的温度场和流场，同时，对双辊铸轧过程中304不锈钢薄带在出口的温度进行了测量，采用此模型，模拟了各种工艺参数对熔液凝固过程的影响，探索适宜的工艺参数值。应用有限元法建立双辊铸轧薄带钢应力场的计算模型，结合流热耦合所获得的温度场，模拟双辊铸轧薄带钢的应力场，分析各种影响因素。通过铸轧薄带钢内的应力分布，研究薄带表面裂纹随工艺参数变化产生的可能性。通过应力场模拟结果，探讨铸轧薄带钢过程中裂纹的形成机理。
双辊铸轧薄带开裂分析表明，铸轧薄带上的裂纹在表面凹痕处产生，并沿柱状晶晶间向内部扩展，且在裂纹附近柱状晶和等轴晶交界处存大量缩孔。铸轧断口表面存在大量氧化物，说明铸轧裂纹在高温时即已产生。通过观察在不同温度下304不锈钢铸轧薄带的金相组织和对室温下304不锈钢的XRD分析，并结合DSC曲线和相图，说明304不锈钢存在高温相变δ→γ。随着温度的升高，304不锈钢抵抗变形的能力减弱，塑性逐渐变好。
对304不锈钢圆柱试样淬火和空冷两种状态下残余应力场进行测量和数值模拟，结果表明，二者吻合较好，证明了所建模型的有效性。采用这一模型对不同时间和不同位置的温度场和应力场进行了数值模拟。淬火试样在开始冷却时，其表面表现出切向拉应力，中部表现为切向压应力。随着冷却时间的延长行，试样应力逐渐减小，最终减少至零。随后，其表面转变为切向压应力，中心转变为切向拉应力。在此过程中，试样的应力逐渐增大。当冷却时间为90s时，试样的应力表现为残余应力。空冷试样在开始冷却时表面表现为切向拉应力，心部表现为切向压应力。随着冷却时间的延长，试样的拉应力和压应力均逐渐减小。当试样冷却至1800s时，其表面和心部的应力值非常小，均接近于零，此时的应力为残余应力。
对双辊铸轧不锈钢薄带在一定铸轧参数下出口温度的实验测量结果与有限元数值模拟结果进行对比发现，二者的吻合性较好，证明了所建模型的有效性。利用所建模型，对不同铸轧参数下的温度场和流场进行了模拟。铸轧速度越大，铸轧薄带出口温度越高，钢液凝固点的位置越低；浇注温度越高，熔池的整体温度和薄带的出口温度均升高，钢液凝固点的位置越低；辊径越大，熔池的整体温度下降，钢液凝固点的位置升高；薄带越厚，熔池内整体温度升高，凝固点的位置下降。
利用流热耦合数值模拟所获得的温度场，模拟了铸轧薄带出口以上和铸轧薄带出口以下的应力场。铸轧薄带出口以上的应力场模拟结果表明，最大拉应力出现在薄带与铸轧辊的接触面靠近出口的位置；最大压应力出现在薄带中心靠近出口的位置。模拟了各种工艺参数对铸轧薄带出口以上应力场的影响。随着铸轧速度的增大，沿接触面的整体应力减小，出口整体拉应力值和压应力值均减小，薄带表面和中心的应力差减小；随着浇注温度的升高，接触面上的整体应力减小，但出口的应力分布曲线接近重合，说明浇注温度对出口处的应力影响很小；随着辊径的增大，沿接触面的整体应力增加，但出口的应力分布曲线接近重合，说明辊径变化对出口处的应力影响很小；随着带厚的增加，最大应力出现位置的弧度降低，沿出口厚度方向整体应力值均增大。
铸轧薄带出口以下的应力场模拟结果表明，薄带冷却初期，薄带的心部温度高于表面温度。随着冷却时间的延长，试样心部和表面温度均降低，薄带的中心与表面温差越来越小。此外，在冷却过程中，试样表面在长度方向的应力表现为拉应力，心部表现为为压应力。当冷却时间延长时，表面拉应力逐渐减小，最终减小至零；随后，其应力状态转变为压应力，中心压应力减小至零随后转变为拉应力，并且应力值逐渐增大。
The specimen was taken from the strip of the304stainless steel after twin-roll stripcasting. The microstructure and fractograph of the specimen was observed by OM andSEM. The phase structure of the specimen were deterimined by XRD. Meanwhile, the DSCcurve of304stainless steel during the cooling process was measured. The stress-straincurves of304stainless steel at different temperatures were measured by thermo-simulatingmachine and its dilatometric curve was determined too.
The residual stress fields of the column specimens after quenching and air coolingwere measured, and the FEM of them was built and the stress fields were simulated. Thesimulated results were compared with the measured one.
The FEM of the coupling fields between the temperature and fluid during the stripcasting of304stainless steel was built in this work. By using this model, the temperatureand fluid fields during the strip casting of304stainless steel were simulated. Meanwhile,the temperature of the304stainless steel strip at the exit during twin-roll strip castingprecess was measured. By using this model, the effect of the different technologyparameters on the solidification of the stainless steel was simulated too. Based on abovementioned model, combining simulated temperature field of the304stainless steel strip, thestress field of the304stainless steel strip was simulated too and the effect of differenttechnology parameters on the stress field was discussed in this work.
The crack analysis of the304stainless steel strip during twin-roll strip casting processshows that, the cracks occur at the dent of the strip surface and develop along the dendriticgrain boundary. The large numbers of oxides can been found on the fractograph, whichindicates that the cracks have been appeared at higher temperature. By means of themicrostructure of304stainless steel at different temperatures, the analysis of XRD result,DSC curve and the Fe-C phase diagram, the phase transformation at high temperature fromδ to γ has been carried out. With the increasing of the temperature, the strength of thestainless steel is decreased, while, the plasticity is increased.
The measured residual stresses of the column specimens after quenching and aircooling were compared with the simulated ones and they are closer to each other, whichproves the validity of this model. By using this model, the temperature and fluid fields atdifferent times and at different location of the specimen were simulated. The simulated results show that, for quenching specimen, at the beginning of the cooling process, thetangential tensile stress appears on the surface, while, tangential compress one at the center.With the increasing of the time, the stress is changed to zero, then, the tangential compressstress is appeared on the surface, while, tangential tensile one at the center, and the stress ischanged greatly. When the time is90s, the stress is the residual one. For the air coolingspecimen, at the begining of the cooling process, the tangential tensile stress is appeared onthe surface, while, tangential compress one at the center. With the increasing of the time,both of the stresses on the surface and center are decreased. When the time is1800s, thoseare very small, which are close to zero, and can be taken as residual one.
The measured temperature of the304stainless steel strip at the exit during twin-rollcasting process was compared with the simulated one, and they are closer to each other,which proves the validity of this model. By using this model, the effect of differenttechnology parameters on the temperature field was simulated. The results show that, thefaster the casting speed is, the higher the temperature of the strip at the exit and the lowerthe position of the freezing point are. Meanwhile, the higher the casting temperature is, thehigher the temperatures of the whole melting pool and the exit of the strip, and the lowerthe position of the freezing point are. Moreover, the larger the radius of the roller is, thelower the temperatures of the whole melting pool and the higher the position of the freezingpoint are. In addition, the thicker the strip is, the higher the temperatures of the wholemelting pool and the lower the position of the freezing point are.
Based on the temperature field simulated by the coupling ones during the twin-rollstrip casting of304stainless steel, the stress fields both upper and under the exit of the stripwere simulated. The simulated result of the stress field upper the exit of the strip shows that,the largest tensile stress is appeared on the contact interface between strip and the roller,which is near the exit, while, the largest compress stress is appeared at the location of thestrip center. The effect of different technology parameters on the stress field upper the exitof the strip was simulated. The faster the casting speed is, the lower the stress along thecontact interface and the lower both the tensile and compress stresses at the exit of the stripare. Meanwhile, the higher the casting temperature is, the lower the stress along the contactinterface is, however, little effect can be found at the exit of the strip. Moreover, the largerthe radius of the roller is, the higher the stress along the contact interface is, however, littleeffect can be found at the exit of the strip. In addition, the thicker the strip is, the lower thelocation of the roller radian is, at which the largest stress is appeared and the higher the stress along the direction of the strip thickness is.
The simulated result of the temperature and stress fields under the exit of the stripshows that, for the temperature field, at the beginning of the cooling process, thetemperature at the strip center is higher than that on strip surface. With the increasing of thecooling time, the temperatures at both strip center and surface are decreassed. For the stressfield, at the beginning of the cooling process, the tensile stress is appeared on the stripsurface, while, the compress one at the center.. With the increasing of the cooling time, thetensile stress on the strip surface is decreased into zero, then increased into compress stress,however, the compress stress at the strip center is decreased into zero, then increased intotensile stress.
引文
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