CN104212969A - Steel pipe continuous quenching process control method based on numerical simulation - Google Patents
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Abstract
The invention relates to a steel pipe continuous quenching process control method based on numerical simulation. The method comprises the following steps that initial technological parameters of the continuous induction quenching process are calculated according to the moving linear speed and quenching cooling water spraying pressure of a steel pipe, and the initial technological parameters comprise a heating process technological parameter and a quenching process technological parameter; finite element analysis is carried out on the steel pipe continuous induction heating process, and the relation between the heating process technological parameter and the internal and external surface temperature of the steel pipe is obtained; finite element analysis is carried out on the steel pipe quenching cooling process, and the relation between the quenching process technological parameter and the steel pipe tissue distribution condition is obtained; according to the process control requirement, the heating process technological parameter and the quenching process technological parameter conforming to the technological control requirement are obtained, and a final steel pipe continuous induction quenching process control parameter is formed; the obtained control parameter is used for controlling the actual steel pipe continuous quenching process. Compared with the prior art, the method has the advantages of reducing energy consumption caused by technological parameter determining through preproduction, improving the working efficiency and the like.
Description
Technical field
The present invention relates to the continuous quenching technology of a kind of steel pipe, especially relate to the continuous quenching process control method of a kind of steel pipe based on numerical simulation.
Background technology
Steel tube quench thermal treatment plays a part very important for the lifting of steel pipe integral performance.Its quenching technology is that steel pipe is heated to austenitizing temperature, after making it all or part of austenitizing, is chilled to below Ms point soon with the speed being greater than critical cooling velocity.After quench cooled, steel pipe be organized as martensite, bainite and a small amount of residual austenite body tissue.
The continuous heat treatment apparatus of current domestic steel pipe is mainly stepped start-stop system flame furnace or resistance furnace.This mode of production technique is simple, equipment cost is lower, but energy consumption is higher, seriously polluted.When using this equipment to heat-treat, need strict control steel pipe length.In addition, because heat-up time is longer, the efficiency of continuous flow procedure is reduced greatly.Under the modern industrialization trend that energy-saving and emission-reduction are the theme, this mode of production by progressively eliminate by new heat treatment mode.
The Joule-Lenz's law of electromagnetic inductive heating principle mainly Faraday's electromagnetic indution law and heating effect of current.When reguline metal is in the magnetic field of change in induction furnace, in metal block, inducing eddy-current can be produced.Because metal resistor chip is minimum, eddy current is usually very strong, and discharges a large amount of heats, utilizes this vortex heat to carry out heating of metal in induction furnace just.
Induction heating process cleans is pollution-free, and by Digital Circuit Control, can easily be automated continuous seepage completely.In the oxidation of induction heating rear surface seldom, substantially do not have decarburization, steel pipe visual appearance is good for steel pipe.In induction heating heat treatment process, heat-up time is very short, heats up very fast, continuous heat treatment ultrahigh in efficiency.In addition, induction heating thermal source is workpiece itself, and thermosteresis is less.According to statistics, the low 30%-50% of induction heating energy consuming ratio flame furnace, the low 20%-30% of ratio resistance stove.
External induction heat treatment stove obtains application and development in the thermal treatment of steel pipe especially petroleum steel pipe at present.As Long Sita Iron And Steel Company of the U.S. and Kawasaki, Japan Iron And Steel Company all use intermediate-frequency induction heating stove.Domestic Anshan iron and steel plant and Xining special steel etc. have also been referred in steel pipe's production.But steel pipe exists physical field complexity in induction heat treatment production process, material property parameter and inductive electromagnetic Parameters variation are large, quenching structure and the feature such as performance difference is remarkable.Therefore, require higher to equipment and process.In formulation induction heat treatment process, general use experience---the method for trial and error carrys out adjusting process parameter, has larger randomness and irrationality at present, and the cost causing equipment and process design increases greatly.Chinese patent application " a kind of intermediate-frequency induction heating device of steel pipe and heat treating method thereof " (Patent publication No: CN 1023638535A) provides a kind of intermediate-frequency induction heating device and heat treating method thereof of thin-wall steel tube.Induction heating is carried out to the thin-wall seamless pipe of wall thickness about 2mm and only needs 2s to 1200 DEG C.But for the steel pipe that wall thickness is larger, due to surface action, its section temperature differs greatly.Nearly outside surface temperature rise rate is far above inner temperature rise rate.The larger temperature difference, will cause steel pipe to be heated uneven, and cause quenching soft spot, hardness not enough, severe patient will cause cracking, and therefore range of application compares limitation.
Steel pipe induction heat treatment process be and many things field of complexity, high temperature, dynamic and instantaneous process, even if utilize special sensing detecting instrument to be also difficult to observe the physicals change of material internal.Therefore, research is optimized to the processing parameter of steel pipe in induction heat treatment production process very necessary.
Summary of the invention
Object of the present invention be exactly in order to overcome above-mentioned prior art exist defect and provide a kind of steel pipe continuous induction hardening process Parameters design, utilize method for numerical simulation, the quality of prediction product, reduce test number (TN), Optimizing Process Parameters, and then determine best process design parameter, be reduced by trial-production and determine the energy consumption that processing parameter causes, increase work efficiency.
Object of the present invention can be achieved through the following technical solutions:
The continuous quenching process control method of steel pipe based on numerical simulation, the continuous quenching process of described steel pipe comprises:
Steel pipe continuous induction heating process: steel pipe is with certain linear velocity translational motion on carrying roller, and premenstrual aligning tractor traction pulls, and enter in inductor block group and carry out austenitizing, heating terminates through air cooling section naturally cooling;
Steel tube quench process of cooling: steel pipe enters jet quenching cooling room, cooling forms martensite or bainite structure;
Described control method specifically comprises the following steps:
Step one, according to steel pipe movement linear velocity and quench cooled irrigation pressure, calculate the processing parameter that continuous induction hardening process is initial, comprise heat-processed processing parameter and quenching process processing parameter;
Step 2, finite element analysis is carried out to the continuous induction heating process of steel pipe, obtain the relation between heat-processed processing parameter and steel pipe surfaces externally and internally temperature;
Step 3, finite element analysis is carried out to steel tube quench process of cooling, obtain the relation between quenching process processing parameter and steel pipe tissue distribution patterns;
Step 4, according to process control needs and step 2, three result, obtain the heat-processed processing parameter and the quenching process processing parameter that meet process control needs, form final steel pipe continuous induction hardening process control parameters;
Step 5, with step 4 obtain controling parameters control the continuous quenching process of actual steel pipe.
Described heat-processed processing parameter comprises heat-up time, air cooling time and coil magnetization electric current and frequency;
Described quenching process processing parameter comprises quench cooled time and the coefficient of heat transfer between steel pipe and quenchant.
Described step 2 is specially:
201) geometric model of steel pipe, ruhmkorff coil and air is set up;
202) relative magnetic permeability of the magnetic permeability of steel pipe in 20-1000 DEG C of temperature range, resistivity, thermal conductivity, specific heat capacity and density and ruhmkorff coil and air is obtained;
203) calculate the surface action degree of depth of steel pipe, carry out stress and strain model according to this degree of depth, during grid division, mesh-density is outwards successively decreased by steel tube surface;
The calculation formula of described surface action degree of depth δ is as follows:
Wherein, ρ is the resistivity of steel pipe, μ
rfor the relative magnetic permeability of steel pipe, f is coil magnetization power frequency;
204) induction heating operating mode is set, load step is set according to the heat-processed processing parameter that step one calculates;
205) carry out grid inspection and physical examination, judge whether to there is mistake, if so, then point out error message, if not, then perform step 206);
206) temperature changing conditions and outer surface of steel tube and the internal surface temperature difference changing conditions in time in time in each stage of induction heating is preserved.
Described step 201) in, when setting up steel pipe and ruhmkorff coil model, Moving Objects model is equivalent to stationary objects model.
Described step 204) in, arrange that induction heating operating mode comprises that setting air outer edge magnetic potential is zero, setting coil magnetization electric current and frequency, heat exchange coefficient between setting air and steel pipe and radiation coefficient.
Described step 3 is specially:
301) the steel pipe model of quench cooled process is set up;
302) hexahedron eight node unit is adopted to carry out stress and strain model;
303) specific heat of steel pipe in 20-1000 DEG C of temperature range, thermal conductivity, enthalpy of phase change and transition kinetics parameter is obtained;
304) final condition of quenching process is set;
305) the quenching process processing parameter calculated according to step one arranges quench cooled load step;
306) carry out grid inspection and physical examination, judge whether to there is mistake, if so, then point out error message, if not, then perform step 307);
307) preserve temperature in quench cooled process over time situation and steel tube quench terminate after tissue distribution patterns.
Described step 301) in, when setting up steel pipe model, using steel pipe cross section as computation model.
In described step 4, process control needs is: in heat-processed, the temperature difference of steel pipe surfaces externally and internally reaches setting range and tissue distribution after steel tube quench reaches setting range.
Compared with prior art, beneficial effect of the present invention is:
1, the continuous induction hardening equipment of steel pipe that the present invention adopts is Multi-stage heating, multistage process for cooling, decreases the steel pipe temperature difference in heat treatment process.
2, the present invention is by combining Computer Numerical Simulation and actual process layout drawing technology effective, the advantage of comprehensive performance Computer Numerical Simulation in simulation and prediction, to realize the optimization of the continuous induction hardening process design of steel pipe, with the process parameter control steel pipe continuous induction hardening process after optimization, decrease and determine the energy consumption that processing parameter causes to improve working efficiency by trial-production.
Accompanying drawing explanation
Fig. 1 is the steel pipe continuous induction hardening set technique floor plan schematic diagram that the embodiment of the present invention adopts;
Fig. 2 is spray cooling chamber structural representation in the embodiment of the present invention;
Fig. 3 is the schematic flow sheet of control method of the present invention;
Fig. 4 is steel pipe symmetry model schematic diagram;
Fig. 5 is ruhmkorff coil group symmetry model schematic diagram;
Fig. 6 is steel pipe cross-sectional model schematic diagram;
Fig. 7 is steel pipe induction heating process surfaces externally and internally temperature schematic diagram;
Fig. 8 is cross section temperature distribution schematic diagram from inside to outside after steel pipe induction heating;
Fig. 9 is air cooling cross section temperature distribution schematic diagram from inside to outside after 1 second after steel pipe induction heating;
Figure 10 is steel pipe cross section radially each position tissue distribution schematic diagram under 0.3MPa irrigation pressure;
Figure 11 is steel pipe cross section radially each position tissue distribution schematic diagram under 0.5MPa irrigation pressure.
In figure: 1, front aligning tractor, 2, induction heater group, 3, carrying roller, 4, steel pipe, 5, air cooling section, the 6, first jet quenching cooling room, the 7, second jet quenching cooling room, 8, power control pod with middle frequency, 9, low-frequency power housing, 10, nozzle, 11, quench cooled chamber outer wall.
Embodiment
Below in conjunction with the drawings and specific embodiments, the present invention is described in detail.The present embodiment is implemented premised on technical solution of the present invention, give detailed embodiment and concrete operating process, but protection scope of the present invention is not limited to following embodiment.
As depicted in figs. 1 and 2, the steel pipe continuous induction hardening complexes that the embodiment of the present invention adopts comprise the front aligning tractor 1, induction heater group 2 and the jet quenching cooling room that connect successively.Induction heater group 2 is 14 groups of separate induction heaters, and first 10 groups is low frequency heating section, is controlled by two low-frequency power housings 9; Latter 4 groups is heating in medium frequency section, is controlled by two power control pod with middle frequency 8.Often organize between induction heater and be equipped with a bipyramid V-type carrying roller 3, carrying roller bus angle is 135 °.Often organize induction heater to be made up of the coil that 10 structures are identical, coil section is rectangle, wide 22mm, high 20mm, thick 4.5mm, coil assembly internal diameter 305mm, each coil-span 30mm.Often organize inductor block actual effective interaction length 750mm, spacing 950mm.
One section of air cooling section 5 is had between induction heater group 2 and jet quenching cooling room.
Quenching process adopts the distribution of two stage split quench cooled room, comprises the first jet quenching cooling room 6 and the second jet quenching cooling room 7 be connected, and each jet quenching cooling room is circumferentially arranged into spray circle by the spray gun that 12 spraying pressures are adjustable.
The continuous quenching process of steel pipe is specially: the weldless steel tube material of 12m length is 35CrMo, external diameter 139.7mm, wall thickness 7.72mm, steel pipe 4 is with certain linear velocity translational motion on carrying roller, premenstrual aligning tractor traction pulls, and enters in inductor block group and carries out austenitizing; Heating terminates rear air cooling section naturally cooling, and the temperature difference is decreased within zone of reasonableness, completes the continuous induction heating process of steel pipe; Steel pipe enters jet quenching cooling room, and jet quenching cooling room forms spray circle by nozzle 10 circumferentially, and quench cooled chamber outer wall 11 section of outline is regular hexagon, is quickly cooled to M to the steel pipe after austenitizing in high-pressure water mist
sbelow point, form martensite or bainite structure, complete steel tube quench process of cooling.
As shown in Figure 3, the continuous quenching process of the steel pipe based on the numerical simulation control method that the embodiment of the present invention provides, comprises the following steps:
Step one, according to steel pipe movement linear velocity and quench cooled irrigation pressure, calculate the processing parameter that continuous induction hardening process is initial, comprise heat-processed processing parameter and quenching process processing parameter.Heat-processed processing parameter comprises heat-up time, air cooling time and coil magnetization electric current and frequency; Quenching process processing parameter comprises quench cooled time and the coefficient of heat transfer between steel pipe and quenchant.
In the present embodiment, steel pipeline speed gets 300mm/s, then often organizing induction furnace heat-up time is 2.5s, and interval cooling time is 3.17s.1-10 group induction furnace working current is 4750A, and induction frequencies is 500Hz; 11-14 group induction furnace working current is 6350A, and induction frequencies is 800Hz.Process of cooling is: first time and second time water spraying time are 4s, and twice water spray is spaced apart 2s.Physical device quenching only has an air cooling of spraying water for 2 times with centre.But consider after leaving quenching apparatus section, steel pipe still may generating portion phase transformation, cause final tissue and just left the tissue of section of quenching and inconsistent.Thus supplement one section of air cooling, the time is set as 2 minutes, determines final tissue distribution so that calculate.
Step 2, finite element analysis is carried out to the continuous induction heating process of steel pipe, obtain the relation between heat-processed processing parameter and steel pipe surfaces externally and internally temperature, as Figure 7-9, Fig. 7 is heat-processed surfaces externally and internally temperature variation diagram in time, Fig. 8 is that heat-processed terminates rear surfaces externally and internally temperature profile, and Fig. 9 is surfaces externally and internally temperature profile after 1s air cooling.
The present embodiment adopts commercial Flux software to simulate, specific as follows:
201) geometric model of steel pipe, ruhmkorff coil and air is set up.Ruhmkorff coil and steel pipe all have axisymmetric feature, steel pipe arbitrary cross section all experiences almost on all four induction heating process in by coil process, thus change the equivalence of Moving Objects model into stationary objects to calculate, simplify three-dimensional model is two-dimensional axisymmetric model modeling simultaneously.Utilize Flux front processor module to carry out modeling or read in geometric model from other modeling software, as shown in fig. 4-5.
202) relative magnetic permeability of the magnetic permeability of steel pipe in 20-1000 DEG C of temperature range, resistivity, thermal conductivity, specific heat capacity and density and ruhmkorff coil and air is obtained.
203) use the Skin Depth of Flux Supervisor to calculate the surface action degree of depth of steel pipe, carry out stress and strain model according to this degree of depth, during grid division, mesh-density is outwards successively decreased by steel tube surface.
The calculation formula of surface action degree of depth δ is as follows:
Wherein, ρ is the resistivity of steel pipe, μ
rfor the relative magnetic permeability of steel pipe, f is coil magnetization power frequency.
204) induction heating operating mode is set, comprise that setting air outer edge magnetic potential is zero, setting coil magnetization electric current and frequency, heat exchange coefficient between setting air and steel pipe and radiation coefficient, give different model areas by the material of definition, and load step is set according to the heat-processed processing parameter that step one calculates.
205) carry out grid inspection and physical examination, judge whether to there is mistake, if so, then point out error message, and get rid of, if not, then start to perform computer finite element solving, perform step 206).
206) temperature changing conditions and outer surface of steel tube and the internal surface temperature difference changing conditions in time in time in each stage of induction heating is preserved.
Step 3, finite element analysis is carried out to steel tube quench process of cooling, obtain the relation between quenching process processing parameter and steel pipe tissue distribution patterns, as shown in figs. 10-11, Figure 10 is after 0.3MPa hydraulic pressure spray quenching cooling terminates, steel pipe cross section is each position tissue distribution figure radially, Figure 11 is that after 0.5MPa hydraulic pressure spray quenching cooling terminates, steel pipe cross section is each position tissue distribution figure radially.
The present embodiment adopts MSC.MARC software and phase transformation sub-routine thereof to simulate, specific as follows:
301) the steel pipe model of quench cooled process is set up.Consider that in actual quenching process, steel pipe is uniform motion on a production line, along its length, the quenching situation of each position is similar to completely the same, thus can carry out suitable simplification to computation model, only get steel pipe cross section (length 1mm) as computation model, as shown in Figure 6.
302) hexahedron eight node unit is adopted to carry out stress and strain model.
303) specific heat of steel pipe in 20-1000 DEG C of temperature range, thermal conductivity, enthalpy of phase change and transition kinetics parameter (TTT curve) is obtained.
304) final condition of quenching process is set.Its outer surface is sprayed water or air heat-exchange effect, by the coefficient of heat transfer between third boundary condition setting steel pipe and quenchant; Internal surface, only by air heat-exchange effect, sets the coefficient of heat transfer between steel pipe and air by third boundary condition.
305) the quenching process processing parameter calculated according to step one arranges quench cooled load step, and the initial temperature arranging steel pipe is 900 DEG C.
306) carry out grid inspection and physical examination, judge whether to there is mistake, if so, then point out error message, if not, then start to perform computer finite element solving, perform step 307);
307) preserve temperature in quench cooled process over time situation and steel tube quench terminate after tissue distribution patterns.
Step 4, according to process control needs and step 2, three result, obtain the heat-processed processing parameter and the quenching process processing parameter that meet process control needs, form final steel pipe continuous induction hardening process control parameters.
Process control needs is: in heat-processed, the temperature difference of steel pipe surfaces externally and internally reaches setting range and tissue distribution after steel tube quench reaches setting range.As in the present embodiment, outside surface 880-950 DEG C, interior table 830-900 DEG C at the end of requiring heating, after air cooling section 5, the steel pipe surfaces externally and internally temperature difference is not higher than 5 DEG C.
Step 5, with step 4 obtain controling parameters control the continuous quenching process of actual steel pipe.
Can be obtained by Fig. 7-9, after heating terminates, the surfaces externally and internally temperature difference reaches 16.4 DEG C, and after 1s air cooling, the temperature difference reduces to 6.87 DEG C, reaches necessary requirement.The roller-way length being converted into air cooling section this time is 300mm, considers miscalculation and safety factors, and the roller-way length that suggestion is arranged should get more than 2 times of 300mm.
From Figure 10 and Figure 11, spraying hydraulic pressure directly changes the effect of quenching, and if hydraulic pressure is 0.3MPa, final tissue is bainite substantially, and increases hydraulic pressure to 0.5MPa, then be finally organized as martensite.Therefore, as needed the final quenching structure of steel pipe to be bainite, then need the spraying hydraulic pressure setting less (0.3MPa); Accordingly, quenching structure as final in needs is martensite, then need to adopt the spraying hydraulic pressure of comparatively large (0.5MPa).
Claims (8)
1., based on the continuous quenching process control method of steel pipe of numerical simulation, it is characterized in that, the continuous quenching process of described steel pipe comprises:
Steel pipe continuous induction heating process: steel pipe is with certain linear velocity translational motion on carrying roller, and premenstrual aligning tractor traction pulls, and enter in inductor block group and carry out austenitizing, heating terminates through air cooling section naturally cooling;
Steel tube quench process of cooling: steel pipe enters jet quenching cooling room, cooling forms martensite or bainite structure;
Described control method specifically comprises the following steps:
Step one, according to steel pipe movement linear velocity and quench cooled irrigation pressure, calculate the processing parameter that continuous induction hardening process is initial, comprise heat-processed processing parameter and quenching process processing parameter;
Step 2, finite element analysis is carried out to the continuous induction heating process of steel pipe, obtain the relation between heat-processed processing parameter and steel pipe surfaces externally and internally temperature;
Step 3, finite element analysis is carried out to steel tube quench process of cooling, obtain the relation between quenching process processing parameter and steel pipe tissue distribution patterns;
Step 4, according to process control needs and step 2, three result, obtain the heat-processed processing parameter and the quenching process processing parameter that meet process control needs, form final steel pipe continuous induction hardening process control parameters;
Step 5, with step 4 obtain controling parameters control the continuous quenching process of actual steel pipe.
2. the continuous quenching process control method of a kind of steel pipe based on numerical simulation according to claim 1, it is characterized in that, described heat-processed processing parameter comprises heat-up time, air cooling time and coil magnetization electric current and frequency;
Described quenching process processing parameter comprises quench cooled time and the coefficient of heat transfer between steel pipe and quenchant.
3. the continuous quenching process control method of a kind of steel pipe based on numerical simulation according to claim 1, it is characterized in that, described step 2 is specially:
201) geometric model of steel pipe, ruhmkorff coil and air is set up;
202) relative magnetic permeability of the magnetic permeability of steel pipe in 20-1000 DEG C of temperature range, resistivity, thermal conductivity, specific heat capacity and density and ruhmkorff coil and air is obtained;
203) calculate the surface action degree of depth of steel pipe, carry out stress and strain model according to this degree of depth, during grid division, mesh-density is outwards successively decreased by steel tube surface;
The calculation formula of described surface action degree of depth δ is as follows:
Wherein, ρ is the resistivity of steel pipe, μ
rfor the relative magnetic permeability of steel pipe, f is coil magnetization power frequency;
204) induction heating operating mode is set, load step is set according to the heat-processed processing parameter that step one calculates;
205) carry out grid inspection and physical examination, judge whether to there is mistake, if so, then point out error message, if not, then perform step 206);
206) temperature changing conditions and outer surface of steel tube and the internal surface temperature difference changing conditions in time in time in each stage of induction heating is preserved.
4. the continuous quenching process control method of a kind of steel pipe based on numerical simulation according to claim 3, is characterized in that, described step 201) in, when setting up steel pipe and ruhmkorff coil model, Moving Objects model is equivalent to stationary objects model.
5. the continuous quenching process control method of a kind of steel pipe based on numerical simulation according to claim 3, it is characterized in that, described step 204) in, arrange that induction heating operating mode comprises that setting air outer edge magnetic potential is zero, setting coil magnetization electric current and frequency, heat exchange coefficient between setting air and steel pipe and radiation coefficient.
6. the continuous quenching process control method of a kind of steel pipe based on numerical simulation according to claim 1, it is characterized in that, described step 3 is specially:
301) the steel pipe model of quench cooled process is set up;
302) hexahedron eight node unit is adopted to carry out stress and strain model;
303) specific heat of steel pipe in 20-1000 DEG C of temperature range, thermal conductivity, enthalpy of phase change and transition kinetics parameter is obtained;
304) final condition of quenching process is set;
305) the quenching process processing parameter calculated according to step one arranges quench cooled load step;
306) carry out grid inspection and physical examination, judge whether to there is mistake, if so, then point out error message, if not, then perform step 307);
307) preserve temperature in quench cooled process over time situation and steel tube quench terminate after tissue distribution patterns.
7. the continuous quenching process control method of a kind of steel pipe based on numerical simulation according to claim 6, is characterized in that, described step 301) in, when setting up steel pipe model, using steel pipe cross section as computation model.
8. the continuous quenching process control method of a kind of steel pipe based on numerical simulation according to claim 1, it is characterized in that, in described step 4, process control needs is: in heat-processed, the temperature difference of steel pipe surfaces externally and internally reaches setting range and tissue distribution after steel tube quench reaches setting range.
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