臺灣博碩士論文加值系統

在熱軋製程中鋼胚會經過數次的平軋來裁減的厚度以及邊軋來修整寬度。Sizing Press側壓裁寬製程是以鍛錘週期性的鎚打鋼胚來裁減寬度，改變了以往邊軋製程連續性的裁減的方式。由於鍛錘對鋼胚裁寬為週期性的進行，裁寬後鋼胚鋼胚呈現週期性的變形。由於Sizing Press製程裁減量比邊軋製程大，且容易調整裁減量，應用在熱軋製程上對於鋼胚尺寸可以有更多的選擇。
本研究運用有限元素軟體ABAQUS依照實際情形修正Sizing Press裁寬壓力機模型，比較元素分割對計算結果收斂性的影響，以及比較顯式積分和隱式積分計算結果差異。接下來建立Sizing Press後續多道次輥軋模型，探討鋼胚不同元素分割經過Sizing Press裁寬後再經過一道次平軋裁減計算結果收斂性。為了縮短計算時間，在模型中假設鋼胚在不同進給速度但在相同應變率的應力-應變行為下，探討模擬中增加鋼胚進給速度對計算時間的影響以及計算結果差異的範圍。
由於熱軋現場鋼胚加熱爐設置在熱軋線的側面，造成鋼胚開始裁減前在寬度方向有溫度梯度，經過Sizing Press裁寬後鋼胚出現縱向彎曲現象，再經過平軋後縱向彎曲現象會更嚴重，影響加工品質。因此以數值模擬的方式探討鋼胚寬度方向有溫度梯度情況下加工結果，並且尋找在這情況下修正縱向彎曲的方法。此外藉由裂紋敏感性試驗探討材料的成型極限。以找出最佳製程條件參數維持熱軋後鋼胚形狀與尺寸之穩定性。

In hot rolling process, the slab thickness gradually reduces by horizontal rolling and the slab width reduces by edge rolling . In contrast to the continuous width reduction during horizontal rolling with conventional vertical edge rollers, sizing press process uses dies to reduce slab width periodically, which results in a discontinuous deformation in the slab. Since the reduction capability of sizing press process can be much larger than edge rolling process, and the amount of reduction can be easily controlled, applying sizing press process to hot rolling provides a more flexible choice of the slab size.
In this study, the ABAQUS finite element model of sizing press is first revised to approach to the real situation. Different mesh sizes may affect the convergence of the results. Comparison between implicit and explicit model had also been studied. In order to achieve a more efficient computation with reasonable computation time, a model with identical material flow properties is simulated with various feeding speed, and then the effect of the feeding speed on the overall computation time and the error of the results was discussed.
Temperature gradient along the width of the slab can not be avoided due to the fact that the furnace in located beside the hot rolling line. With the presence of temperature gradient, camber phenomenon occurs on the slab after sizing press process. The elongated slab becomes arc-shaped. The camber phenomenon becomes more serious after the horizontal roll process. To overcome this problem, the ABAQUS FE-model in applied to simulate the sizing press process with existing temperature gradient, and technique can be proposed accordingly to reverse the camber phenomenon. The strain induced crack opening (SICO) test had also been carried out to obtain the metal forming limit. Better processing parameters can be proposed to according the results.

第一章 緒論 1
1-1 前言 1
1-2 文獻回顧 5
1-2-1 有限元素法在金屬塑性加工之相關研究 5
1-2-2 輥軋製程相關研究 6
1-2-3 Sizing Press側壓裁寬製程相關研究 7
1-3 研究動機與目的 9
第二章 塑性變形理論與軋延製程介紹 11
2-1 塑性加工 11
2-1-1 彈塑性變形行為 12
2-1-2 等效應力及等效應變 13
2-1-3 材料降伏準則之比較 14
2-2 有限元素基本理論 16
2-2-1 顯式積分法 17
2-2-2 隱式積分法 18
2-3 熱軋加工流程介紹 20
2-3-1 熱軋加工流程及Sizing Press裁寬流程 20
2-3-2 Sizing Press裁寬壓力機鍛錘幾何關係及運動軌跡 21
第三章 研究方法與實驗步驟 25
3-1 研究步驟 25
3-2 研究流程圖 27
3-3 Gleeble 1500動態模擬試驗機 28
3-4 Gleeble鍛粗試驗 30
3-5 鋼鐵熱延性與裂紋敏感性實驗 31
第四章 數值模擬軟體及模型 34
4-1 數值模擬軟體 34
4-2 熱軋加工模型 37
4-2-1 修改前Sizing Press裁寬壓力機模型架構 37
4-2-2 修改後之模型 40
4-2-3 SAE1016低碳鋼高溫應力應變曲線 44
4-2-4 Gleeble鍛粗試驗之有限元素模擬 45
第五章 結果討論 48
5-1 Sizing Press裁寬壓力機模型修改後對鋼胚裁減結果之影響 48
5-1-1 修改前後模型之比對 48
5-1-2 模型修改前後鋼胚裁寬模擬之後外形與等效塑性應變之比對 51
5-2 鋼胚元素分割大小對計算結果收斂性之影響 54
5-3 隱式積分及顯式積分計算結果之差異 60
5-4 鋼胚表面絕熱與非絕熱對Sizing Press裁寬結果之影響 67
5-5 Sizing Press模型的鋼胚進給速度對計算結果之影響 73
5-6 Sizing Press之後一號粗軋機平軋模擬結果之探討 78
5-6-1 鋼胚元素分割對Sizing Press之後一號粗軋機平軋結果之影響 78
5-6-2 Sizing Press之後鋼胚進給速度對一號粗軋機結果之影響 82
5-7 鋼胚寬度方向溫度梯度對裁減結果之影響 85
5-7-1 鋼胚寬度方向不同溫度梯度對Sizing Press裁減結果的影響 85
5-7-2 鋼胚寬度方向溫度梯度為0.0185℃/mm經過Sizing Press及一道次平軋裁減結果 92
5-7-3 鋼胚寬度方向有溫度梯度經過Sizing Press及粗軋機上輥輪不同傾斜角度裁減結
果 94
5-8 鋼胚經Sizing Press、一號粗軋機、二號粗軋機、二號邊軋機及三號邊軋機裁減結果 99
5-9 裂紋敏感性試驗 105
第六章 結論與未來研究方向 107
6-1 結論 108
6-2 未來研究方向 111
參考文獻 112

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