CN106644464A - Rolling mill transmission system key component fatigue life early warning method based on load spectrum analysis - Google Patents
Rolling mill transmission system key component fatigue life early warning method based on load spectrum analysis Download PDFInfo
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Abstract
The invention discloses a rolling mill transmission system key component fatigue life early warning method based on load spectrum analysis. The method is characterized by comprising the following steps: 1, obtaining a rolling mill transmission system key component load spectrum through real-time monitoring in a rolling mill working process; 2, based on a computer simulation technology, obtaining a stress distribution and conversion coefficient of a rolling mill transmission system key component; 3, obtaining a corresponding stress spectrum by performing conversion processing on the load spectrum measured in the first step; 4, compiling an equivalent stress amplitude histogram by performing statistics on the stress spectrum after processing in the third step by use of a cyclic rain flow counting method; and 5, calculating fatigue life circulation frequency of a transmission part by use of a correction Miner method, and converting the fatigue life circulation frequency into a fatigue life taking a year as a unit. The method solves the problems of large calculation amount and high calculation complexity in a conventional fatigue life calculation method, has quite high applicability and operability and is high in engineering practicality.
Description
Technical field
The present invention relates to metallurgical machinery, Structural Metallic Fatigue life-span calculate correlative technology field, especially a kind of part longevity
Life Forecasting Methodology, the fatigue life early warning of specifically a kind of rolling mill transmission system key components and parts based on load analysis of spectrum
Method, it is particularly well-suited to calculate the fatigue life of rolling mill transmission system key components and parts in the operation of rolling.
Background technology
Rolling mill transmission system is the significant components of milling train, and its strength and stability directly influences the normal operation of milling train.
During mill milling, when rolled piece is nipped and dished out, milling train will bear huge impact torque load, so that milling train
Transmission system produce fatigue damage.Once the parts of the transmission system of milling train are damaged, Rolling Production will stop immediately
Only, larger economic loss is caused, while there is certain potential safety hazard.It is therefore desirable to proposing a kind of effective, quick and accurate
The key components and parts of rolling mill transmission system are carried out the prediction and early warning of fatigue life by true method for early warning.
At present, for be mostly in the fatigue damage research of rolling mill transmission system key components and parts by stable rolling torque or
The nominal torque of main motor carries out Calculation of Fatigue Life analysis as load, but thus obtained loading spectrum and milling train reality
Suffered loading spectrum is inconsistent, and this will cause the budget life-span larger with actual conditions error.Load in the present invention in the rolling cycle
Spectrum is obtained by the actual measurement to the parameters in milling train actual production, therefore its result of calculation is relatively reliable, accurate.But
In actual production, the data volume of the loading spectrum obtained by actual measurement is very huge, if directly these loading spectrums to be used for into fatigue life
Prediction, calculating process becomes very complicated, and the present invention is then aimed at the loading spectrum of actual measurement, it is carried out effective, quick
Conversion, analysis, extract and obtain after compression is processed effectively, the loading spectrum that significantly reduces of data volume, bond material afterwards
Rolling mill transmission system key components and parts are carried out fatigue life prediction by damage parameters with amendment Miner, Jack John Thomas rule.Therefore, this
The calculating process of the fatigue life of bright middle rolling mill transmission system key components and parts is simple and quick, and result of calculation is accurately and reliably.
The content of the invention
The purpose of the present invention is to be mostly in the fatigue damage research for existing rolling mill transmission system key components and parts
Calculation of Fatigue Life analysis, thus obtained load are carried out using the nominal torque of stable rolling torque or main motor as load
Spectrum suffered loading spectrum actual with milling train is inconsistent, and is easily caused budget life-span and the larger problem of actual conditions error, invention one
The fatigue life method for early warning based on the rolling mill transmission system key components and parts of load analysis of spectrum is planted, with effective, quick and accurate
The fatigue life prediction for carrying out rolling mill transmission system key components and parts.
The technical scheme is that：
A kind of fatigue life method for early warning of the rolling mill transmission system key components and parts based on load analysis of spectrum, its feature exists
In the fatigue life that mill drive part effectively, fast and accurately can be predicted according to actual loaded situation, the reality of the system
Now comprise the following steps：
(1) by the real-time monitoring in the milling train course of work, obtaining rolling mill transmission system key components and parts in rolling week
Suffered loading spectrum in phase；
(2) threedimensional model and FEM model of transmission device are set up based on computer simulation technique, mill drive is obtained
The stress distribution law and stress of system core parts and the conversion coefficient of load；
(3) based on the stress obtained in step (2) and the conversion coefficient of load, to load measured in step (1)
Spectrum carries out conversion process, obtains corresponding stress spectra, and the stress spectra to obtaining carries out waveform separation, compression denoising and peak-to-valley value
The process of extraction；
(4) stress spectra after process in step (3) is counted using circulation rain flow method, and the knot based on statistics
Fruit develops equivalent stress amplitude histogram；
(5) according to the equivalent stress amplitude histogram worked out in step (4), the fatigue behaviour parameter of bond material, application
Amendment Miner, Jack John Thomas rule calculates the fatigue life cycles number of times of rolling mill transmission system key components and parts, and converts it to and be with year
The fatigue life of unit.
In step (1) of the present invention, the rolling cycle refers to from rolled piece and is bitten into the whole process dished out, what actual measurement was obtained
Loading spectrum is the loading spectrum in multiple rolling cycles suffered by rolling mill transmission system key components and parts.
In step (2) of the present invention, the threedimensional model and finite element of transmission device are set up based on computer simulation technique
Model, comprises the steps：
(1) mill drive axle system is measured, rolling mill transmission system key components and parts is set up according to measured data
Threedimensional model and FEM model, model includes but is not limited to cross universal spiale, long torque axis and cross universal spiale jaw,
As shown in figure 1, and according to actual conditions added material parameter and boundary condition；
(2) statics Analysis are carried out by load boundary condition of the average load operating mode in the rolling cycle, obtains static(al) and make
With the stress distribution situation of lower transmission system；
(3) statics Analysis are carried out as load boundary condition using different torques, obtains corresponding stress distribution situation；
(4) above-mentioned calculating and simulation process are all based on rolling mill transmission system key components and parts small deformation it is assumed that i.e. arbitrary
Arbitrary components of strain of parts are less than 5%.
In step (2) of the present invention, the threedimensional model and finite element of transmission device are set up based on computer simulation technique
Model, its purpose is to the stress distribution situation according to suffered by rolling mill transmission system key components and parts, find out fatigue damage collection
In position, while obtaining the conversion coefficient of stress and load, the computing formula of conversion coefficient is：
In formula, k is the conversion coefficient between stress and load, MPa/kNm；MijMoment of torsion suffered by part, kNm；σijFor
With MijFor the calculated part maximum stress value of load boundary condition, MPa.
In step (3) of the present invention, the foundation of stress spectra denoising is that stress causes fatigue damage to parts
Contribution degree, its method is four-point method algorithm, its objective is to delete low contribution amount Cyclic Stress of the amplitude less than threshold value, is treated with compressing
The stress spectra of process, reduces amount of calculation.
In step (3) of the present invention, peak-to-valley value is extracted and refers to the flex point for extracting composition Cyclic Stress in stress spectra, its side
Method is triangle test, its objective is to delete the non-flex point that fatigue life is not affected in stress spectra, further to compress pending
Stress spectra, reduce amount of calculation.
In step (4) of the present invention, stress spectra is counted using circulation rain flow method, and the knot based on statistics
Fruit develops equivalent stress amplitude histogram, and its concrete steps includes：
(1) stress spectra obtained in step (3) is counted using circulation rain flow method, obtains the width of Cyclic Stress
Value SaiWith average SmiAnd its corresponding cycle-index naiAnd nmi。
(2) equivalent turn is carried out to the amplitude and average of the Cyclic Stress of the acquisition in rain-flow counting based on Goodman diagram
Change, obtain equivalent stress amplitude.
In step (5) of the present invention, the fatigue behaviour parameter of material includes：Fatigue limit σ of material-1With survival rate
(confidence level) relevant material parameter apAnd bp, effective stress concentration factor Kσ, absolute dimensional factor ε, surface machining factor β with
And fatigue safety factor n-1。
In step (5) of the present invention, Theory of The Cumulative Fatigue Damage is amendment Miner, Jack John Thomas rule, and its computing formula is：
In formula, PiFor stress rank σ in equivalent stress spectrumiProbability；NiFor simple stress σiOccur material under effect tired
The stress-number of cycles of labor destruction, can obtain according to revised material p-S-N curve computing formula；NAlwaysFor under loading spectrum effect
The fatigue life cycles number of times of the rolling mill transmission system key components and parts of estimation.
In step (5) of the present invention, revised material p-S-N curve computing formula are：
In formula, ap、bpFor the material parameter that survival rate is p；σ-1For fatigue strength limit；NpFor survival rate be p when fatigue
Life-span.
In step (5) of the present invention, the conversion formula for being converted to the fatigue life in units of year is：
In formula, n is the fatigue life counted in units of year；N is that Miner, Jack John Thomas rule formula is calculated to be rolled by correcting
The fatigue life cycles number of times of machine transmission system key components and parts；N0For the number of times rolled in milling train 1 year.
The invention has the beneficial effects as follows：
The present invention effectively, fast and accurately according to actual loaded situation can predict rolling mill transmission system key components and parts
Fatigue life.
The present invention is on the basis of the accuracy for ensureing Calculation results, by Finite element analysis results and mathematical statistics side
Method combines, and the loading spectrum to surveying is analyzed and compresses, and solves computationally intensive in existing fatigue life calculation method, meter
The problems such as calculating complicated, with higher applicability and operability, engineering practicability is strong.
Description of the drawings
Fig. 1 is the three-dimensional finite element model of cross universal spiale involved in the present invention and long torque axis.
Fig. 2 is the fatigue life method for early warning techniqueflow chart of the mill drive part of the present invention.
Fig. 3 is that the load spectrogram for obtaining is surveyed in present example.
Fig. 4 is the stress spectrogram obtained after treatment in present example.
Fig. 5 is amplitude histogram (a), the equal value histogram of the Cyclic Stress obtained through rain-flow counting in present example
(b) and the stereogram (c) of synthesis.
Fig. 6 is the equivalent stress amplitude histogram obtained in present example.
Specific embodiment
The present invention is further illustrated below in conjunction with the drawings and specific embodiments.
Below by example to a kind of the tired of rolling mill transmission system key components and parts based on load analysis of spectrum of the invention
Labor life-span method for early warning elaborates.
Idea of the invention is that, the loading spectrum that actual measurement is obtained effectively and rapidly is changed, should to what is be converted to
Power spectrum carries out waveform separation, compression denoising, peak-to-valley value extraction and mathematical statistics, equivalent stress spectrum histogram is obtained, afterwards with this
Based on, the fatigue behaviour parameter of bond material carries out fatigue using amendment Miner, Jack John Thomas rule to transmission system key components and parts
Life prediction.In the present invention, the calculating process simple and fast of fatigue life, result of calculation is accurately and reliably.
Referring to Fig. 2.
A kind of fatigue life method for early warning of the rolling mill transmission system key components and parts based on load analysis of spectrum, including it is as follows
Step：
1. by the real-time monitoring in the milling train course of work, obtaining rolling mill transmission system key components and parts in the rolling cycle
Interior suffered loading spectrum；
In the present invention, the rolling cycle refers to from rolled piece and is bitten into the whole process dished out, and surveying the loading spectrum for obtaining is
Loading spectrum in multiple rolling cycles suffered by rolling mill transmission system key components and parts.Actual measurement in this example obtains loading spectrum such as Fig. 3 institutes
Show.
2. the threedimensional model and FEM model of transmission device are set up based on computer simulation technique, mill drive system is obtained
The stress distribution law and stress of system key components and parts and the conversion coefficient of load；
The step of threedimensional model and FEM model that transmission device is set up based on computer simulation technique is：
(1) mill drive axle system is measured, rolling mill transmission system key components and parts is set up according to measured data
Threedimensional model and FEM model, the threedimensional model and FEM model of transmission system key components and parts include but is not limited to cross
Universal-joint spindle, long torque axis and cross universal spiale jaw, as shown in figure 1, and should according to actual conditions added material parameter and
Boundary condition；
(2) statics Analysis are carried out by load boundary condition of the average load operating mode in the rolling cycle, obtains static(al) and make
With the stress distribution situation of lower transmission system；
(3) statics Analysis are carried out as load boundary condition using different torques, obtains corresponding stress distribution situation；
(4) above-mentioned calculating and simulation process are all based on rolling mill transmission system key components and parts small deformation it is assumed that i.e. arbitrary
Arbitrary components of strain of parts are less than 5%.
Stress distribution according to suffered by rolling mill transmission system key components and parts, finds out the position of fatigue damage concentration, while
According to using different torques as load boundary condition, the conversion coefficient of stress and load is obtained, in this example, the stress for calculating
Spectrum conversion coefficient is k=0.1025MPa/kNm.
3., based on the stress obtained in step 2 and the conversion coefficient of load, loading spectrum measured in step 1 is carried out
Conversion process, obtains corresponding stress spectra, and the stress spectra to obtaining carries out what waveform separation, compression denoising and peak-to-valley value were extracted
Process；
In the present invention, the foundation of stress spectra denoising is the contribution degree that stress causes fatigue damage to parts, its
Method is four-point method algorithm, its objective is to delete low contribution amount Cyclic Stress of the amplitude less than threshold value, to compress pending answering
Power is composed, and reduces amount of calculation.Stress spectra peak-to-valley value is extracted and refers to the flex point for extracting composition Cyclic Stress in stress spectra, and its method is three
Point comparison method, its objective is to delete the non-flex point that fatigue life is not affected in stress spectra, further to compress pending stress
Spectrum, reduces amount of calculation.In this example, the stress spectra after process is as shown in Figure 4.
4. the stress spectra after process in step 3 is counted using circulation rain flow method, and the result based on statistics
Develop equivalent stress amplitude histogram；
Stress spectra is counted using circulation rain flow method, and equivalent stress amplitude is developed based on the result of statistics
Histogrammic concrete steps include：
(1) stress spectra obtained in step 3 is counted using circulation rain flow method, obtains the amplitude of Cyclic Stress
SaiWith average SmiAnd its corresponding cycle-index naiAnd nmi, the result after this step statistics is shown in figure in histogrammic form
5。
(2) equivalent turn is carried out to the amplitude and average of the Cyclic Stress of the acquisition in rain-flow counting based on Goodman diagram
Change, obtain equivalent stress amplitude.
In this example, the equivalent stress amplitude histogram of acquisition is shown in Fig. 6.
5. according to the equivalent stress amplitude histogram worked out in step 4, the fatigue behaviour parameter of bond material, using amendment
Miner, Jack John Thomas rule calculates the fatigue life cycles number of times of rolling mill transmission system key components and parts, and converts it in units of year
Fatigue life.
In the present invention, the fatigue behaviour parameter of material includes：Fatigue limit σ of material-1Have with survival rate (confidence level)
Material parameter a of passpAnd bp, effective stress concentration factor Kσ, absolute dimensional factor ε, surface machining factor β and fatigue safety
Factor of n-1.It is the parameter for considering all of above impact Calculation of Fatigue Life in this example, as shown in table 2.1.
The relevant parameter of the power transmission shaft of table 2.1
Amendment Miner, Jack John Thomas rule computing formula be：
In formula, PiFor stress rank σ in equivalent stress spectrumiProbability；NiFor simple stress σiOccur material under effect tired
The stress-number of cycles of labor destruction, can obtain according to revised material p-S-N curve computing formula；NAlwaysFor under loading spectrum effect
The fatigue life cycles number of times of the rolling mill transmission system key components and parts of estimation.
Revised material p-S-N curve computing formula are：
In formula, ap、bpFor the material parameter that survival rate is p；σ-1For fatigue strength limit；NpFor survival rate be p when fatigue
Life-span.
In step 5 of the present invention, the conversion formula for being converted to the fatigue life in units of year is：
In formula, n is the fatigue life counted in units of year；N is to pass using the calculated milling train of amendment Miner, Jack John Thomas rule
The fatigue life cycles number of times of dynamic system core parts；N0For the number of times rolled in milling train 1 year.
After being analyzed to the operating mode of the milling train in this example, obtain the number of times that milling train rolled in 1 year and be about 1080000
It is secondary.In this example, it is 5688031 times, i.e., 5.267 using the calculated fatigue life cycles number of times of amendment Miner, Jack John Thomas rule
Year.
Below only an example of the present invention is described, but is not to be construed as limiting the scope of the invention.This
Bright to be not only limited to above example, during its Calculation of Fatigue Life, the fatigue life parameter of object allows to change.In a word, it is all
The various change made in the protection domain of independent claims of the present invention is within the scope of the present invention.
Part that the present invention does not relate to is same as the prior art or can be realized using prior art.
Claims (10)
1. a kind of fatigue life method for early warning of the rolling mill transmission system key components and parts based on load analysis of spectrum, it is characterised in that
It is comprised the following steps：
(1) by the real-time monitoring in the milling train course of work, obtaining rolling mill transmission system key components and parts within the rolling cycle
Suffered loading spectrum；
(2) threedimensional model and FEM model of mill drive device are set up based on computer simulation technique, mill drive is obtained
The stress distribution law and stress of system core parts and the conversion coefficient of load；
(3) based on the stress obtained in step (2) and the conversion coefficient of load, loading spectrum measured in step (1) is entered
Row conversion process, obtains corresponding stress spectra, and the stress spectra to obtaining carries out waveform separation, compression denoising and peak-to-valley value and extracts
Process；
(4) stress spectra after process in step (3) is counted using circulation rain flow method, and the result based on statistics is compiled
Make equivalent stress amplitude histogram；
(5) according to the equivalent stress amplitude histogram worked out in step (4), the fatigue behaviour parameter of bond material, using amendment
Miner, Jack John Thomas rule calculates the fatigue life cycles number of times of rolling mill transmission system key components and parts, and converts it in units of year
Fatigue life, conversion formula is：
In formula, n is the fatigue life counted in units of year；N is to pass using the calculated milling train of amendment Miner, Jack John Thomas rule formula
The fatigue life cycles number of times of dynamic system core parts；N0For the number of times rolled in milling train 1 year.
2. method according to claim 1, it is characterised in that：Rolling cycle described in step (1) refers to from rolled piece and is nipped
To the whole process dished out, it is in multiple rolling cycles suffered by rolling mill transmission system key components and parts to survey the loading spectrum for obtaining
Loading spectrum.
3. method according to claim 1, it is characterised in that：The described foundation based on computer simulation technique of step (2) is passed
The threedimensional model and FEM model of dynamic device, comprises the steps：
(1) mill drive axle system is measured, the three-dimensional of rolling mill transmission system key components and parts is set up according to measured data
Model and FEM model, transmission system key components and parts include cross universal spiale, long torque axis and cross universal spiale fork
Head, and should be according to actual conditions added material parameter and boundary condition；
(2) statics Analysis are carried out by load boundary condition of the average load operating mode in the rolling cycle, under obtaining Static behavior
The stress distribution situation of transmission system；
(3) statics Analysis are carried out as load boundary condition using different torques, obtains corresponding stress distribution situation；
(4) above-mentioned calculating and simulation process are all based on rolling mill transmission system key components and parts small deformation it is assumed that i.e. arbitrary zero
Arbitrary components of strain of part are less than 5%.
4. method according to claim 1, it is characterised in that：The described foundation based on computer simulation technique of step (2) is passed
The threedimensional model and FEM model of dynamic device, its purpose is to the stress according to suffered by rolling mill transmission system key components and parts
Distribution, finds out the position of fatigue damage concentration, while the conversion coefficient of stress and load is obtained, the computing formula of conversion coefficient
For：
In formula, k is the conversion coefficient between stress and load, MPa/kNm；MijMoment of torsion suffered by part, kNm；σijIt is with Mij
For the calculated part maximum stress value of load boundary condition, MPa.
5. method according to claim 1, it is characterised in that：The foundation of the stress spectra denoising described in step (3) is
Stress causes the contribution degree of fatigue damage to parts, and its method is four-point method algorithm, its objective is that deleting amplitude is less than threshold value
Low contribution amount Cyclic Stress, to compress pending stress spectra, reduce amount of calculation.
6. method according to claim 1, it is characterised in that：Peak-to-valley value described in step (3) is extracted and refers to extraction stress
The flex point of Cyclic Stress is constituted in spectrum, its method is triangle test, its objective is to delete in stress spectra does not affect fatigue life
Non- flex point, further to compress pending stress spectra, reduce amount of calculation.
7. method according to claim 1, it is characterised in that：Application circulation rain flow method correspondence described in step (4)
Power spectrum is counted, and develops equivalent stress amplitude histogram based on the result of statistics, and its concrete steps includes：
(1) stress spectra obtained in step (3) is counted using circulation rain flow method, obtains amplitude S of Cyclic Stressai
With average SmiAnd its corresponding cycle-index naiAnd nmi；
(2) equivalency transform is carried out to the amplitude and average of the Cyclic Stress of the acquisition in rain-flow counting based on Goodman diagram, is obtained
Take equivalent stress amplitude.
8. method according to claim 1, it is characterised in that：The fatigue behaviour parameter of the material described in step (5) includes：
Fatigue limit σ of material-1It is relevant material parameter a of confidence level with survival ratepAnd bp, effective stress concentration factor Kσ, definitely
Size factor ε, surface machining factor β and fatigue safety factor n-1。
9. method according to claim 1, it is characterised in that：The calculating of the amendment Miner, Jack John Thomas rule described in step (5) is public
Formula is：
In formula, PiFor stress rank σ in equivalent stress spectrumiProbability；NiFor simple stress σiMake material that fatigue occurs under effect broken
Bad stress-number of cycles, can obtain according to revised material p-S-N curve computing formula；NAlwaysFor the lower estimation of loading spectrum effect
Rolling mill transmission system key components and parts fatigue life cycles number of times.
10. method according to claim 9, it is characterised in that：Revised material p-S-N curve computing formula are：
In formula, ap、bpFor the material parameter that survival rate is p；σ-1For fatigue strength limit；NpFor survival rate be p when the tired longevity
Life.
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