CN109719241B - Short-process casting and forging integrated process for steel - Google Patents
Short-process casting and forging integrated process for steel Download PDFInfo
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- CN109719241B CN109719241B CN201811389374.1A CN201811389374A CN109719241B CN 109719241 B CN109719241 B CN 109719241B CN 201811389374 A CN201811389374 A CN 201811389374A CN 109719241 B CN109719241 B CN 109719241B
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Abstract
The invention discloses a short-flow casting and forging integrated process of steel, which comprises the steps of accurate analog calculation of liquid core rate of a steel ingot, casting of the liquid core steel ingot, water seal of a riser, demoulding by high-temperature hot delivery and forging of the liquid core of the steel ingot, and breaks through the traditional process method of reheating and forging after the steel ingot is completely solidified, simplifies the process flow, saves the working procedures of cooling, annealing and heating before forging of the steel ingot, reduces the heating times of a forge piece, organically combines the solidification and deformation processes, and carries out semi-solid forging and forming when the steel ingot is not completely solidified and has the liquid core, thereby realizing the short-flow casting and forging integrated technology of the steel ingot; the advantages of computer simulation and digitization technology are fully utilized, the computer simulation calculation of the whole process of steel ingot casting and forging is realized, the liquid core rate is accurately controlled, a special technology is adopted to accelerate the cooling and the skull solidification of a riser, and the novel technology of steel ingot ultra-high temperature demoulding, hot delivery and liquid core forging is realized; provides a new way for effectively eliminating shrinkage porosity of steel ingots and improving segregation and structure refinement.
Description
Technical Field
The invention relates to the technical field of metal casting and forging, in particular to a short-process casting and forging integrated process for steel, which can realize green, environment-friendly, short-process, low-cost, high-efficiency and high-quality forging of the steel.
Background
With the rapid development of the fields of ocean engineering, nuclear power, wind power, coal chemical industry and the like in China, equipment develops towards the direction of large units, high performance and high requirements, the demand of forgings is larger and larger, the traditional preparation process flow of the large forgings is long, and the forging of steel ingots follows the production flow of smelting, ingot casting, natural cooling, annealing, heating and forging. The traditional forging method has the defects of solidification segregation, shrinkage cavity, looseness, cracks and the like of the steel ingot, the poured steel ingot needs to consume a large amount of heat energy after being naturally cooled or annealed and then heated for forging, and the traditional forging method has the problems of multiple working procedures, long flow, high energy consumption, low efficiency, unstable quality and the like, and restricts the development of equipment manufacturing industry.
Disclosure of Invention
The invention aims to provide a short-process casting and forging integrated process for steel, which can effectively eliminate shrinkage porosity of a steel ingot, improve segregation and structure refinement, shorten the forging process of the steel ingot, reduce the heating or heating times of a forge piece and save energy.
In order to achieve the purpose, the technical scheme adopted by the invention is as follows:
a short-process casting and forging integrated process for steel comprises the following steps: smelting, ingot casting, water sealing riser, high-temperature hot delivery demoulding and liquid core forging, and specifically comprises the following steps:
firstly, accurately simulating and calculating the liquid core rate of a steel ingot: carrying out three-dimensional modeling on the cast and forged steel ingot by using a computer, carrying out simulation calculation on temperature field and stress displacement change in the steel ingot mold filling process, natural cooling, bottom plate changing and water seal riser stage, carrying out calculation on temperature field and fluid motion change in the high-temperature hot delivery demolding stage, carrying out semisolid forming forging simulation on the steel ingot with liquid core, determining the change rate of the liquid core rate in different stages, accurately controlling time nodes and selecting process parameters; the change of the liquid core rate of the steel ingot is controlled in the way that the liquid core rate is 30-40% when the steel ingot is naturally cooled to a bottom plate replacement, the liquid core rate is 12-20% when a riser is sealed by water, the liquid core rate is 6-12% when the steel ingot is lifted and conveyed, the liquid core rate is 5-10% when the steel ingot is demolded, the liquid core rate is 3-8% when the liquid core is forged, and the specific time is different according to steel types and ingot types; determining the liquidus temperature and the solidus temperature of the steel;
step two, smelting and casting the liquid core steel ingot: pouring the smelted molten steel into an inverted-cone steel ingot mold, controlling the pouring temperature of a steel ingot to be 50-60 ℃ above the liquidus temperature, controlling the mold filling time of an ingot body to be 15min, and controlling the mold filling time of a riser to be 10 min; changing a bottom plate when the liquid core rate of the steel ingot is 30-40%, naturally cooling to 12-20% and then spraying water to the riser, stopping spraying water to the riser when the liquid core rate is reduced to 6-12%, controlling the water spraying time to be 15-30min, and ensuring that the solidified and crusted edge of the riser is not less than 100mm and the shell has enough thickness and strength;
step three, high-temperature hoisting, hot conveying and demolding: the steel ingot after the water seal riser head and the ingot mould are together hot-fed from a smelting workshop to a forging workshop through a flat car and a heat preservation cover through a hot-feeding channel for demoulding, the hot-feeding and demoulding time is controlled to be 15-30min, the liquid core rate of the steel ingot after high-temperature demoulding is controlled to be 5-10%, the surface temperature of the steel ingot after demoulding is not lower than 1100 ℃, the core temperature is not lower than 1300 ℃, and then liquid core forging can be carried out; if the temperature is lower than the temperature, the steel is heated to 1250 ℃ of the initial forging temperature of the steel and then forged;
step four, forging the liquid core of the steel ingot: adopting a whole compacting process of the wide and thick plate, covering heat-preservation cotton on the surface of the demoulded steel ingot, and immediately forging the steel ingot by a press; controlling the liquid core rate to be 3-8% when the steel ingot begins to be forged; compacting by adopting a wide thick plate, controlling the rolling reduction at 10-20% each time, maintaining the pressure for 10min, and compacting by adopting a wide flat anvil at the later stage; when the steel ingot is forged, the steel ingot is completely solidified so as to ensure the safety and reliability and stable quality of the forging process;
and step five, performing subsequent hot forging by adopting a conventional forging technology.
Preferably, the precise simulation calculation of the liquid core rate in the first step comprises three-dimensional modeling, temperature field calculation is carried out on each stage of the filling process, natural cooling, bottom plate temperature equalization, riser water sealing, high-temperature hot delivery, demolding and liquid core forging of the inverted-taper steel ingot mold by using casting molding simulation software-THERCAST software, a file generated by the casting molding simulation software-THERCAST software is introduced into forging simulation software-FORGE software, semisolid molding forging simulation with the liquid core is carried out by using the forging simulation software-FORGE software, the change of the liquid core rate in different stages and accurate control time nodes are determined, and technological parameters of the whole process of the liquid core forging of the steel ingot are determined by backstepping according to simulation results.
Preferably, the three-dimensional modeling is steel ingot three-dimensional modeling by adopting SolidWorks or ProE software, a middle injection pipe and a cross pouring channel in an ingot mold are omitted in the modeling process, a covering agent, a heat insulation plate, molten steel, the ingot mold and a chassis are reserved, 1/8 of the ingot mold is selected as a calculation object in order to simplify the simulation calculation workload and consider the symmetry of the ingot mold, the grid is divided into-180 ten thousand grid units, the grid is refined in a partial region, a 1/8 model is required to be reduced into an integral model for forging after the ingot mold is demolded, and the grid is divided into-320 ten thousand grid units; aiming at different objects and calculation precisions concerned by different steel ingot solidification stages, the selected models are different: for the integral solidification of the steel ingot, only the temperature field is selected for calculation, so that the evolution rule of the temperature field is integrally mastered, and a basic basis is provided for determining time nodes at each stage of liquid core forging; considering calculation precision and concerned objects for solidification in each stage, simultaneously considering temperature field and stress displacement change for the mold filling process, natural cooling, chassis temperature equalization and water seal riser stages, and considering temperature field and fluid motion change for the hot conveying stage; the mold filling and natural cooling process simultaneously comprises a heat insulation plate, a covering agent, an ingot mold, a steel ingot and a base plate, the influence of the covering agent is removed in a water seal riser stage, and the influence of the base plate and the covering agent is removed in a high-temperature heat delivery stage.
Preferably, the selection of simulation parameters and the determination of boundary conditions in the three-dimensional modeling process: aiming at different steel grades, material attribute parameters of the system are selected for calculation, and the density of the covering agent and the density of the heat insulation plate are respectively 500 kg/m and 1000kg/m3The chassis and the ingot mould are made of cast iron materials; the superheat degree is 50-60 ℃, and the initial temperature of an ingot mold is set to be 150 ℃; in the simulation, the heat exchange condition between the whole model and the outside is air cooling, and the heat exchange condition between the molten steel, the ingot mold and the chassis before the chassis is replaced is normal heat exchange; after the chassis is replaced, the low heat exchange and even heat insulation conditions are formed between the chassis and other parts; when the riser is sealed by water, the covering agent is removed, and the top of the molten steel and the outside are in a water cooling condition; in the hot conveying stage, the covering agent and the chassis are removed, and air cooling conditions are set; and in the liquid core forging stage, the default of the wide and thick plate for forging and compacting is set as rigidity, and the heat transfer condition between the steel ingot and the forging die is set as a software default state.
Preferably, the accurate simulation calculation of the liquid core rate adopts casting molding simulation software-THERCAST software and forging simulation software-FORGE software to carry out simulation calculation, stl files of a covering agent, a heat insulation board, molten steel, an ingot mold and a chassis are introduced in the pretreatment of the casting molding simulation software-THERCAST software, simulation calculation is carried out after initial conditions and parameters are selected, and a may file generated by the casting molding simulation software-THERCAST software is input into the forging simulation software-FORGE software to carry out liquid core forging simulation calculation; and (3) calculating a temperature field according to different ingot types and different materials, determining 70%, 90% and 100% of solidification time of the steel ingot, and accurately calculating and determining liquid core rate and time nodes of various stages of steel ingot pouring, natural cooling, chassis exchange, water seal riser, high-temperature hot delivery and liquid core forging according to a temperature field evolution rule, so as to provide guidance for formulating the process.
Preferably, the inverted taper in the inverted taper ingot mold is 5 to 10 °.
Preferably, the hot feeding channel in the third step is arranged between the smelting workshop and the forging workshop, and the length of the hot feeding channel does not exceed 500 meters.
Compared with the prior art, the invention has the advantages and effects that:
1. the process breaks through the traditional process method of reheating forging after the steel ingot is completely solidified, organically combines the solidification and deformation processes, and performs semi-solid forging molding when the steel ingot is not completely solidified and has a liquid core, thereby realizing the short-flow casting and forging integrated technology of the steel ingot;
2. the advantages of computer simulation and digitization technology are fully utilized, the computer simulation calculation of the whole process of steel ingot casting and forging is realized, the liquid core rate is accurately controlled, a special technology is adopted to accelerate the cooling and the skull solidification of a riser, and the novel technology of steel ingot ultra-high temperature demoulding, hot delivery and liquid core forging is realized;
3. the liquid core steel ingot adopts the integral compaction technology of the wide and thick plate, the semi-solid structure with better fluidity of the core part of the steel ingot and the internal and external temperature gradients suitable for forging are fully utilized, and forced filling and compaction closing are carried out under high temperature, high pressure and large deformation, so that the steel ingot segregation is reduced, and the product quality is improved;
4. the traditional ingot mold design is broken through, and the inverted cone ingot mold which is more suitable for liquid core forging is designed;
5. through steel ingot ultra-high temperature hot delivery and liquid core forging, realize waste heat utilization, energy saving and emission reduction, green, reduce the number of heating fires, improve forging efficiency, energy-conservation material saving is showing with increasing efficiency:
(1) the production efficiency is improved, the in-mold time of the steel ingot is reduced by more than 90% compared with the traditional forged steel ingot, the in-mold time of the steel ingot is reduced by 35-45% compared with the conventional hot-feeding heating forging process, the process flow is shortened, the forging time from the completion of the casting to the first heating time is shortened by more than 70%, and the production efficiency is greatly improved;
(2) the service life of the ingot mould is prolonged, the average service life of the ingot mould in the traditional process is only about 60 times, the loss of the ingot mould can be reduced due to the reduction of the mould time, the service life of the ingot mould can be prolonged, and the service life of the ingot mould can be at least prolonged to more than 100 times;
(3) the material utilization rate is improved, because one heating fire number is saved, the burning loss rate of the steel ingot is reduced, and the inverted cone ingot mold reduces a dead head, so that the material utilization rate is improved by 7-10 percent, and the material saving effect is obvious;
(4) the energy-saving effect is remarkable, the liquid core forging saves one heating fire time, and the natural gas per ton of steel is saved by 210-3The cost of natural gas is saved by 565-;
6. the requirement on the tonnage of the press is reduced in the forging process, the forging adaptability is improved, and a large forging piece can be manufactured by using a small press;
7. the method provides a new way for effectively eliminating shrinkage porosity of the steel ingot and improving segregation and structure refinement, and realizes green and environment-friendly forging of steel, short process, low cost and high quality.
Drawings
FIG. 1 is a flow diagram of a process according to the present invention;
FIG. 2 is a schematic flow diagram of a liquid core forging process of the present invention;
FIG. 3 is a schematic view of the structure of an ingot mold according to the present invention.
Detailed Description
The present invention will be described in further detail with reference to the accompanying drawings.
Example 1
Taking a 24-ton 45-steel ingot as an example, the temperature field and the liquid phase distribution condition of each solidification stage of the ingot are simulated and calculated. The method comprises the following specific steps:
step one, three-dimensional modeling: and the SolidWorks or ProE software is adopted to carry out three-dimensional modeling on the steel ingot, so that a middle pouring pipe and a cross gate in the ingot mold are omitted in the modeling process, and only a covering agent, a heat insulation plate, molten steel, the ingot mold and a chassis are reserved. In order to simplify the simulation calculation workload, 1/8 of the ingot mold is selected as a calculation object according to the symmetry of the ingot mold, the grid is divided into 180-ten thousand grid units, the grid is refined in partial region, after the ingot mold is demolded, the 1/8 model is reduced into an integral model for forging process simulation, and the grid is divided into 320-ten thousand grid units. And aiming at different concerned objects and different calculation accuracies at different steel ingot solidification stages, the selected models are different. For the integral solidification, only the temperature field is selected for calculation, so that the evolution rule of the temperature field can be integrally mastered, and a basic basis is provided for determining time nodes of each stage of liquid core forging; considering calculation precision and concerned objects for solidification in each stage, simultaneously considering temperature field and stress displacement change for the stages of the mold filling process, natural cooling, chassis temperature equalization and water seal riser, and considering the change of the temperature field and fluid motion for the stage of high-temperature heat delivery; the mold filling and natural cooling process simultaneously comprises a heat insulation plate, a covering agent, an ingot mold, a steel ingot and a base plate, the influence of the covering agent is removed in the water sealing riser stage, and the influence of the base plate and the covering agent is removed in the high-temperature hot conveying stage.
Secondly, selecting simulation parameters and determining boundary conditions: selecting material attribute parameters of a system to calculate, wherein the density of the covering agent and the density of the heat-insulation plate are respectively 500 kg/m3 and 1000kg/m3, and the chassis and the ingot mould are made of cast iron materials; the superheat degree is 50-60 ℃, and the initial temperature of an ingot mold is set to be 150 ℃; in the simulation, the heat exchange condition between the whole model and the outside is air cooling (air _ cooling), the heat exchange condition between molten steel before changing the chassis, the ingot mold and the chassis is normal heat exchange (mold _ mold _ resistance), but after changing the chassis, the chassis and other parts are in low heat exchange or even heat insulation condition (no _ exchange); when the riser is sealed by water, the covering agent is removed, and the top of the molten steel and the outside are in a water cooling condition; a hot-air stage, in which the covering agent and the base pan are removed, and air-cooling conditions (air _ cooling) are set; and in the liquid core forging stage, the default of the wide and thick plate for forging and compacting is set as rigidity, and the heat transfer condition between the steel ingot and the forging die is set as a software default state (steel-hot-medium).
And thirdly, performing accurate simulation calculation on the liquid core rate, performing simulation calculation by adopting THERCAST software and FORGE software, introducing stl files of a covering agent, a heat-insulating plate, molten steel, an ingot mold and a chassis in the pretreatment of the THERCAST software, performing simulation calculation after selecting initial conditions and parameters, and inputting a may file generated by the THERCAST software into the FORGE software to perform liquid core forging simulation calculation. And (3) performing temperature field calculation according to different ingot types and different materials, determining 70%, 90% and 100% of solidification time, and accurately calculating and determining liquid core rate and time nodes of various stages of steel ingot pouring, natural cooling, chassis exchange, water seal riser, high-temperature hot delivery and liquid core forging according to a temperature field evolution rule, so as to provide guidance for formulating the process. The change of the liquid core rate of the steel ingot is controlled to be 30-40% when the steel ingot is naturally cooled to the bottom plate, 12-20% when the riser is sealed by water, 6-12% when the riser is hot-fed, 5-10% when the steel ingot is demoulded and 3-8% when the liquid core is forged.
Fourthly, determining technological parameters, reversely deducing and determining the technological parameters of the whole process of liquid core forging of the steel ingot according to a simulation result, wherein the liquidus temperature and the solidus temperature of 45 steel are 1496 ℃ and 1415 ℃, the superheat degree is 50 ℃, the solidification time of the 24t steel ingot body and the steel ingot is 7.6h and 10.4h respectively, and the liquid core forging process of the steel is determined according to the simulation calculation result: 1) naturally cooling for 3h20min after pouring, changing the chassis, carrying out uniform temperature for 2h10min after changing the chassis, spraying water on a riser to seal the riser, spraying water on the riser for 20min, then hoisting and conveying at high temperature for 30min, and immediately carrying out liquid core forging after demolding; 2) the corresponding spindle liquid core rate change is controlled as follows: 31.2% -11.4% -9.65% -5.8%; 3) adopting a wide and thick plate to integrally forge, pressing down by 10 percent along the radial direction, wherein the pressing down amount is about 130mm, circularly pressurizing when the plate is not pressed, and continuously maintaining the pressure for 10 min; 4) moving the upper flat plate to leak out of the ingot tail 1/3, performing staggered compaction, keeping the pressure for 10min, and pressing down by 130 mm; 5) continuously moving the upper flat plate to the dead head end, leaking half of the ingot body, keeping the reduction amount at 130mm, and keeping the pressure for 10 min; 6) and when the wide and thick plate is not pressed, removing the upper flat plate, compacting by using a wide flat anvil, returning to 1250 ℃, keeping the temperature for 5 hours, pressing a clamp handle, rotating by 90 degrees, drawing by using the wide flat anvil, trimming to 1100X1100mm square, cutting off the clamp handle, returning to the furnace, and completing the liquid core forging stage. Thereafter, the ingot is forged into a product as a billet by a conventional method.
Example 2
Taking 16Mn steel as an example, the temperature field and the liquid phase distribution condition of each solidification stage of the steel ingot are simulated and calculated. The method comprises the following specific steps:
step one, three-dimensional modeling: and the SolidWorks or ProE software is adopted to carry out three-dimensional modeling on the steel ingot, so that a middle pouring pipe and a cross gate in the ingot mold are omitted in the modeling process, and only a covering agent, a heat insulation plate, molten steel, the ingot mold and a chassis are reserved. In order to simplify the simulation calculation workload, 1/8 of the ingot mold is selected as a calculation object according to the symmetry of the ingot mold, the grid is divided into 180-ten thousand grid units, the grid is refined in partial region, after the ingot mold is demolded, the 1/8 model is reduced into an integral model for forging process simulation, and the grid is divided into 320-ten thousand grid units. And aiming at different concerned objects and different calculation accuracies at different steel ingot solidification stages, the selected models are different. For the integral solidification, only the temperature field is selected for calculation, so that the evolution rule of the temperature field can be integrally mastered, and a basic basis is provided for determining time nodes of each stage of liquid core forging; considering calculation precision and concerned objects for solidification in each stage, simultaneously considering temperature field and stress displacement change for the stages of the mold filling process, natural cooling, chassis temperature equalization and water seal riser, and considering the change of the temperature field and fluid motion for the stage of high-temperature heat delivery; the mold filling and natural cooling process simultaneously comprises a heat insulation plate, a covering agent, an ingot mold, a steel ingot and a base plate, the influence of the covering agent is removed in the water sealing riser stage, and the influence of the base plate and the covering agent is removed in the high-temperature hot conveying stage.
Secondly, selecting simulation parameters and determining boundary conditions: selecting material attribute parameters of a system to calculate, wherein the density of the covering agent and the density of the heat-insulation plate are respectively 500 kg/m3 and 1000kg/m3, and the chassis and the ingot mould are made of cast iron materials; the superheat degree is 50-60 ℃, and the initial temperature of an ingot mold is set to be 150 ℃; in the simulation, the heat exchange condition between the whole model and the outside is air cooling (air _ cooling), the heat exchange condition between molten steel before changing the chassis, the ingot mold and the chassis is normal heat exchange (mold _ mold _ resistance), but after changing the chassis, the chassis and other parts are in low heat exchange or even heat insulation condition (no _ exchange); when the riser is sealed by water, the covering agent is removed, and the top of the molten steel and the outside are in a water cooling condition; a hot-air stage, in which the covering agent and the base pan are removed, and air-cooling conditions (air _ cooling) are set; and in the liquid core forging stage, the default of the wide and thick plate for forging and compacting is set as rigidity, and the heat transfer condition between the steel ingot and the forging die is set as a software default state (steel-hot-medium).
And thirdly, performing accurate simulation calculation on the liquid core rate, performing simulation calculation by adopting THERCAST software and FORGE software, introducing stl files of a covering agent, a heat-insulating plate, molten steel, an ingot mold and a chassis in the pretreatment of the THERCAST software, performing simulation calculation after selecting initial conditions and parameters, and inputting a may file generated by the THERCAST software into the FORGE software to perform liquid core forging simulation calculation. And (3) performing temperature field calculation according to different ingot types and different materials, determining 70%, 90% and 100% of solidification time, and accurately calculating and determining liquid core rate and time nodes of various stages of steel ingot pouring, natural cooling, chassis exchange, water seal riser, high-temperature hot delivery and liquid core forging according to a temperature field evolution rule, so as to provide guidance for formulating the process. The change of the liquid core rate of the steel ingot is controlled to be 30-40% when the steel ingot is naturally cooled to the bottom plate, 12-20% when the riser is sealed by water, 6-12% when the riser is hot-fed, 5-10% when the steel ingot is demoulded and 3-8% when the liquid core is forged.
Fourthly, determining technological parameters, wherein the time for solidifying 70%, 90% and 100% of the ingot body is respectively 3.3h, 5.4h and 7.8h according to the simulation result, and accordingly, establishing a liquid core forging technology: naturally cooling for 3.5h, changing the base plate, and keeping the temperature uniform for 1.5h, wherein the liquid core rate is reduced from 32% to 13.5%; the riser sprays water for 20min, and the liquid core rate is reduced to 8.9%; after the riser is sealed by water, the steel ingot is hot-fed to a forging workshop at a high temperature for demoulding, the hot-feeding time is 30min, and the liquid core rate is reduced to 4 percent; and covering the large cover plate with the liquid core of the steel ingot belt, forging, completely solidifying the steel ingot after 18min, and forging according to a conventional method.
The process breaks through the traditional process method of reheating forging after the steel ingot is completely solidified, organically combines the solidification and deformation processes, and performs semi-solid forging molding when the steel ingot is not completely solidified and has a liquid core, thereby realizing the short-flow casting and forging integrated technology of the steel ingot; the advantages of computer simulation and digitization technology are fully utilized, the computer simulation calculation of the whole process of steel ingot casting and forging is realized, the liquid core rate is accurately controlled, the special technology is adopted to accelerate the cooling and the solidification of a riser, and the novel technology of steel ingot ultra-high temperature demoulding, hot delivery and liquid core forging is realized.
Claims (7)
1. A short-process casting and forging integrated process of steel is characterized in that: the process flow comprises the following steps: smelting, ingot casting, water sealing riser, high-temperature hot delivery demoulding and liquid core forging, and specifically comprises the following steps:
firstly, accurately simulating and calculating the liquid core rate of a steel ingot: carrying out three-dimensional modeling on the cast and forged steel ingot by using a computer, carrying out simulation calculation on temperature field and stress displacement change in the steel ingot mold filling process, natural cooling, bottom plate changing and water seal riser stage, carrying out calculation on temperature field and fluid motion change in the high-temperature hot delivery demolding stage, carrying out semisolid forming forging simulation on the steel ingot with liquid core, determining the change rate of the liquid core rate in different stages, accurately controlling time nodes and selecting process parameters; the change of the liquid core rate of the steel ingot is controlled in the way that the liquid core rate is 30-40% when the steel ingot is naturally cooled to a bottom plate replacement, the liquid core rate is 12-20% when a riser is sealed by water, the liquid core rate is 6-12% when the steel ingot is lifted and conveyed, the liquid core rate is 5-10% when the steel ingot is demolded, the liquid core rate is 3-8% when the liquid core is forged, and the specific time is different according to steel types and ingot types; determining the liquidus temperature and the solidus temperature of the steel;
step two, smelting and casting the liquid core steel ingot: pouring the smelted molten steel into an inverted-cone steel ingot mold, controlling the pouring temperature of a steel ingot to be 50-60 ℃ above the liquidus temperature, controlling the mold filling time of an ingot body to be 15min, and controlling the mold filling time of a riser to be 10 min; changing a bottom plate when the liquid core rate of the steel ingot is 30-40%, naturally cooling to 12-20% and then spraying water to the riser, stopping spraying water to the riser when the liquid core rate is reduced to 6-12%, controlling the water spraying time to be 15-30min, and ensuring that the solidified and crusted edge of the riser is not less than 100mm and the shell has enough thickness and strength;
step three, high-temperature hoisting, hot conveying and demolding: the steel ingot after the water seal riser head and the ingot mould are together hot-fed from a smelting workshop to a forging workshop through a flat car and a heat preservation cover through a hot-feeding channel for demoulding, the hot-feeding and demoulding time is controlled to be 15-30min, the liquid core rate of the steel ingot after high-temperature demoulding is controlled to be 5-10%, the surface temperature of the steel ingot after demoulding is not lower than 1100 ℃, the core temperature is not lower than 1300 ℃, and then liquid core forging can be carried out; if the temperature is lower than the temperature, the steel is heated to 1250 ℃ of the initial forging temperature of the steel and then forged;
step four, forging the liquid core of the steel ingot: adopting a whole compacting process of the wide and thick plate, covering heat-preservation cotton on the surface of the demoulded steel ingot, and immediately forging the steel ingot by a press; controlling the liquid core rate to be 3-8% when the steel ingot begins to be forged; compacting by adopting a wide thick plate, controlling the rolling reduction at 10-20% each time, maintaining the pressure for 10min, and compacting by adopting a wide flat anvil at the later stage; when the steel ingot is forged, the steel ingot is completely solidified so as to ensure the safety and reliability and stable quality of the forging process;
and step five, performing subsequent hot forging by adopting a conventional forging technology.
2. The short-flow casting and forging integrated process of steel as claimed in claim 1, wherein the short-flow casting and forging integrated process comprises the following steps: the precise simulation calculation of the liquid core rate in the first step comprises the steps of three-dimensional modeling, temperature field calculation of the inverted-cone steel ingot mold in each stage of the mold filling process, natural cooling, bottom plate temperature equalization, water seal riser, high-temperature heat delivery, mold release and liquid core forging by using casting molding simulation software-THERCAST software, introduction of a file generated by the casting molding simulation software-THERCAST software into forging simulation software-FORGE software, semi-solid state molding forging simulation with the liquid core by using the forging simulation software-FORGE software, determination of the change of the liquid core rate in different stages and accurate control time nodes, and back-pushing and determining process parameters of the whole process of the liquid core forging of the steel ingot according to simulation results.
3. The short-flow casting and forging integrated process of steel as claimed in claim 2, wherein the short-flow casting and forging integrated process comprises the following steps: the three-dimensional modeling is to adopt SolidWorks or ProE software to carry out steel ingot three-dimensional modeling, a middle injection pipe and a transverse pouring channel in an ingot mould are omitted in the modeling process, a covering agent, a heat insulation plate, molten steel, the ingot mould and a chassis are reserved, 1/8 of the ingot mould is selected as a calculation object in order to simplify the simulation calculation workload and consider the symmetry of the ingot mould, the grid is divided into-180 ten thousand grid units, the grid is refined in a partial region, a 1/8 model is required to be reduced into an integral model to carry out the forging process after the ingot mould is demoulded, and the grid is divided into-320 ten thousand grid units; aiming at different objects and calculation precisions concerned by different steel ingot solidification stages, the selected models are different: for the integral solidification of the steel ingot, only the temperature field is selected for calculation, so that the evolution rule of the temperature field is integrally mastered, and a basic basis is provided for determining time nodes at each stage of liquid core forging; considering calculation precision and concerned objects for solidification in each stage, simultaneously considering temperature field and stress displacement change for the mold filling process, natural cooling, chassis temperature equalization and water seal riser stages, and considering temperature field and fluid motion change for the hot conveying stage; the mold filling and natural cooling process simultaneously comprises a heat insulation plate, a covering agent, an ingot mold, a steel ingot and a base plate, the influence of the covering agent is removed in a water seal riser stage, and the influence of the base plate and the covering agent is removed in a high-temperature heat delivery stage.
4. The short-flow casting and forging integrated process of steel as claimed in claim 3, wherein the short-flow casting and forging integrated process comprises the following steps: selecting simulation parameters and determining boundary conditions in the three-dimensional modeling process: aiming at different steel grades, material attribute parameters of the system are selected for calculation, and the density of the covering agent and the density of the heat insulation plate are respectively 500 kg/m and 1000kg/m3The chassis and the ingot mould are made of cast iron materials; the superheat degree is 50-60 ℃, and the initial temperature of an ingot mold is set to be 150 ℃; in the simulation, the heat exchange condition between the whole model and the outside is air cooling, and the heat exchange condition between the molten steel, the ingot mold and the chassis before the chassis is replaced is normal heat exchange; after the chassis is replaced, the low heat exchange and even heat insulation conditions are formed between the chassis and other parts; when the riser is sealed by water, the covering agent is removed, and the top of the molten steel and the outside are in a water cooling condition; in the hot conveying stage, the covering agent and the chassis are removed, and air cooling conditions are set; and in the liquid core forging stage, the default of the wide and thick plate for forging and compacting is set as rigidity, and the heat transfer condition between the steel ingot and the forging die is set as a software default state.
5. The short-flow casting and forging integrated process of steel as claimed in claim 4, wherein the short-flow casting and forging integrated process comprises the following steps: the accurate simulation calculation of the liquid core rate adopts casting molding simulation software-THERCAST software and forging simulation software-FORGE software to carry out simulation calculation, stl files of a covering agent, a heat insulation plate, molten steel, an ingot mold and a chassis are introduced in the pretreatment of the casting molding simulation software-THERCAST software, simulation calculation is carried out after initial conditions and parameters are selected, and a may file generated by the casting molding simulation software-THERCAST software is input into the forging simulation software-FORGE software to carry out liquid core forging simulation calculation; and (3) calculating a temperature field according to different ingot types and different materials, determining 70%, 90% and 100% of solidification time of the steel ingot, and accurately calculating and determining liquid core rate and time nodes of various stages of steel ingot pouring, natural cooling, chassis exchange, water seal riser, high-temperature hot delivery, demoulding and liquid core forging according to a temperature field evolution rule, so as to provide guidance for formulating the process.
6. The short-flow casting and forging integrated process of steel as claimed in claim 5, wherein the short-flow casting and forging integrated process comprises the following steps: the inverted taper in the inverted taper ingot mould is 5-10 degrees.
7. The short-flow casting and forging integrated process of steel as claimed in claim 6, wherein: and the hot conveying channel in the third step is arranged between the smelting workshop and the forging workshop, and the length of the hot conveying channel is not more than 500 meters.
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| DE202006011370U1 (en) * | 2006-07-25 | 2006-10-05 | Henmetal Corporation | Process to manufacture a stainless steel component by a combination of casting and high-temperature forging |
| CN105268884A (en) * | 2014-07-21 | 2016-01-27 | 中国科学院金属研究所 | Method for forging superhigh-temperature soft core of steel ingot |
| CN108097854A (en) * | 2017-12-04 | 2018-06-01 | 北京科技大学 | A kind of band large-scale metal component high uniformity short route manufacturing process |
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| DE202006011370U1 (en) * | 2006-07-25 | 2006-10-05 | Henmetal Corporation | Process to manufacture a stainless steel component by a combination of casting and high-temperature forging |
| CN105268884A (en) * | 2014-07-21 | 2016-01-27 | 中国科学院金属研究所 | Method for forging superhigh-temperature soft core of steel ingot |
| CN108097854A (en) * | 2017-12-04 | 2018-06-01 | 北京科技大学 | A kind of band large-scale metal component high uniformity short route manufacturing process |
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