CN110929355B - A method of continuous casting slab crack risk prediction and its application - Google Patents
A method of continuous casting slab crack risk prediction and its application Download PDFInfo
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Abstract
一种连铸坯裂纹风险预测的方法及其应用，属于连铸技术领域，该方法因为连铸过程中间裂纹萌生、表面裂纹扩展主要是由拉应变或拉应力引起，故取拉应变作为中间裂纹萌生、表面裂纹扩展判定依据，以高温拉伸测定的临界裂纹准则和连铸从结晶器弯月面到空冷区结束的全流程热/力耦合模型为基础建立了裂纹风险预测模型。采用裂纹风险预测模型分析铸坯在连铸全流程裂纹风险性并绘制裂纹风险云图，进而对现场生产提出工艺对策以控制裂纹缺陷、改善铸坯质量。
A method for predicting the risk of cracks in a continuous casting slab and its application belong to the technical field of continuous casting. Since the initiation of intermediate cracks and the expansion of surface cracks in the continuous casting process are mainly caused by tensile strain or tensile stress, the tensile strain is taken as the intermediate crack. Based on the critical crack criterion of high temperature tensile test and the thermal/mechanical coupling model of the whole process of continuous casting from the mold meniscus to the end of the air cooling zone, a crack risk prediction model was established. The crack risk prediction model is used to analyze the risk of cracks in the whole process of continuous casting and draw the cloud map of crack risk, and then propose process countermeasures for on-site production to control crack defects and improve the quality of the slab.
Description
Technical Field
The invention relates to the technical field of continuous casting, in particular to a method for predicting crack risks of a continuous casting billet and application thereof.
Background
Cracks are one of the main quality problems of continuous casting billets, and the cracks account for about 50% of various defects. In the continuous casting process, the phase transformation of the casting blank, the precipitation behavior of carbonitride in the grain boundary and the performance difference among different structures are the root causes of the formation of cracks. Zero plasticity temperature (ZDT) exists in a high-temperature region, a material near the ZDT temperature is between a solid phase and a liquid phase, the fluidity is poor, the plasticity is low, and cracks are easy to generate in the temperature region; in the low temperature region of the austenite phase, since dynamic recovery and dynamic recrystallization are less likely to occur, cracks are also likely to form during plastic deformation.
The temperature range of brittleness of the steel materials is determined by the reduction of area, and the materials are generally considered to be in the temperature range of brittleness when the reduction of area is less than 60%. Most steel grades have three brittleness areas in the cooling process, namely a first brittleness area, a second brittleness area and a third brittleness area. In the brittle section, the plasticity of the steel is poor, cracks are often formed and spread in the brittle section, and straightening and pressing in the brittle temperature section are avoided in the continuous casting process. The main reason for the cracks formed in the casting blank in the continuous casting process is that the deformation of the casting blank exceeds the material failure limit under the action of external force, thermal stress and the like, so that the crack defects are formed and expanded.
The patent application 201910522577.1 discloses a crack control method for a micro-alloy steel near-net-shape special-shaped continuous casting billet, which researches a crack control method for a micro-alloy steel near-net-shape special-shaped continuous casting billet, and comprises the following steps: in the continuous casting process, rectangular cooling water tanks of copper plates on two sides of a crystallizer are kept unchanged, and the crystallizer is cooled by adopting non-equidistant circular cooling water holes; the covering slag is special covering slag for slow-cooling peritectic steel; the secondary cooling adopts a peritectic steel secondary cooling special model: the secondary cooling strength is 0.48-0.50L/kg. The invention improves the temperature uniformity of the crystallizer copper plate by improving the local heat transfer of the crystallizer, reduces the stress at the R-angle position of the near-net-shape special-shaped blank and controls the crack source of the molten steel in the crystallizer. And developing special covering slag for slow-cooling peritectic steel, establishing a special secondary cooling model for micro-alloy steel, improving the lubricating and heat transfer conditions of the covering slag and improving the quality of the special-shaped blank.
Patent application 201210464148.1 "Cr-containing low alloy steel TDC76 continuous casting billet crack control method", relates to a Cr-containing low alloy steel TDC76 continuous casting billet crack control method, which is characterized in that: the mass percentages of the molten steel at the end point of the converter are that the carbon content is 0.04-0.19%, the phosphorus content is 0.010-0.020%, and the tapping temperature is 1557-1637 ℃; the refining in-place temperature of the LF furnace is 1480-1564 ℃, and the refining out-of-place temperature is 1598-1665 ℃; the deep vacuum time of VD furnace smelting is more than 13min, the deep vacuum degree is less than or equal to 0.10Kpa, and the soft blowing time is 10-17 min; the soft blowing flow rate is 20-99 NL/min; controlling the degree of superheat between 20 and 33 ℃ and the drawing speed between 0.50 and 0.70m/min in continuous casting production; the medium carbon steel covering slag and the secondary cooling area used in the crystallizer of the continuous casting machine are cooled by weak cooling, the continuous casting blank is subjected to slow cooling by a lower-laying upper-cover type stack when being discharged, and the slow cooling time is more than 48 hours, so that the generation of cracks of the continuous casting blank is avoided.
A journal document 'research on transverse corner crack control technology of a microalloy steel wide and thick plate continuous casting billet' published in a microalloy steel continuous casting crack control technology workshop considers that the transverse corner crack of the continuous casting billet is a common production defect, the mechanism of forming and expanding the transverse corner crack is analyzed by combining the practice of producing boron-containing steel A36-1B by a Tian Steel No. 4 wide and thick plate continuous casting machine, the influence of important factors such as high-temperature plasticity of the casting billet, cooling characteristics and arrangement of a secondary cooling nozzle, a secondary cooling process, Al and B element content and the like on the corner crack rate is researched, and corresponding improvement measures are provided. Production practices show that the corner crack defects of the boron-containing steel A36-1B continuous casting billet are effectively controlled.
The foreign document "Critical strain for internal crack formation in continuous casting [ J ]" published on Ironmaking and steelmaking discloses the Critical strain of continuous casting internal cracks, and a series of tensile tests and solidification analyses were performed on ingots having a liquid core. The results show that when the total amount of strain between Zero Strength Temperature (ZST) and zero plasticity temperature (ZDT) exceeds the critical strain, internal cracks develop and propagate, regardless of the mode of deformation, whether continuous or intermittent. From this result, it can be concluded that the conditions for internal crack formation during continuous casting of a cast slab should be evaluated in terms of the total amount of strain between each roll ZST and ZDT, rather than in terms of the increase in strain; on the basis, the prevention measures of the internal cracking of the continuous casting are clarified.
The continuous casting crack control method is a method for reducing the crack initiation risk in the process and theoretically explaining the crack initiation principle, and a method for predicting the crack initiation and evaluating the on-site crack risk cannot be provided.
Disclosure of Invention
Aiming at the problems in the method for controlling the continuous casting billet cracks in the prior art, the invention provides a method for predicting the continuous casting billet crack risk and application thereof, which are used for analyzing the crack risk of the continuous casting billet in the whole continuous casting process and providing technological measures for field production to control crack defects and improve the quality of the casting billet.
The technical scheme of the invention is as follows:
the invention discloses a method for predicting crack risks of a continuous casting billet, which comprises the following steps of:
step 1: critical strain of crack initiation or critical strain of crack propagation of the continuous casting billet is used as a critical crack judgment criterion;
step 2: establishing a continuous casting full-flow heat/force coupling model (a continuous casting full-flow FEM model) from a meniscus of a crystallizer to the end of an air cooling zone in finite element software according to the continuous casting blank to be prepared and the geometric dimensions of a casting roller;
and step 3: and (3) establishing a crack risk prediction model by combining the critical crack judgment criterion determined in the step (1) and the continuous casting full-process heat/force coupling model (continuous casting full-process FEM model) established in the step (2), and drawing a crack risk cloud picture.
In the step 1, in the continuous casting process, the crack initiation and the crack propagation are mainly caused by tensile strain or tensile stress, so that the method selects the tensile strain as a crack initiation and crack propagation judgment basis to determine a critical crack judgment criterion.
In the step 2, the geometric dimensions of the continuous casting blank to be prepared and the casting roller are determined according to actual casting machine parameters, and the roll column coordinates and the diameter of the casting roller are extracted from an actual CAD drawing on site.
In the step 2, the finite element software adopts MSC.
In the step 2, the finite element meshing of the complex continuous casting billet in the finite element software can be a mesh divider of MSC.
In the step 2, the process for establishing the continuous casting full-flow heat/force coupling mold is as follows: firstly, according to a CAD drawing, introducing each parameter for extracting a roller array into MSC.Marc to establish the roller array by using MSC.Marc secondary development function; then, dividing a casting blank entity by using a mesh divider; and moving the established casting blank grid model to the upper opening of the crystallizer, applying boundary conditions and working conditions, and finally establishing a continuous casting full-flow heat/force coupling model from a meniscus of the crystallizer to an air cooling area.
In the step 2, in the continuous casting full-flow heat/force coupling model, the monitored main positions are as follows: the middle surface of the casting blank in the casting direction is used as a monitoring surface, the monitoring surface can more accurately reflect the deformation condition of the casting blank than other positions in a model, and the change condition of the strain and the temperature of each position on the detection surface along with the position of the casting flow is researched.
In the step 3, the method for establishing the crack risk prediction model comprises the following steps: simulating and analyzing heat transfer and deformation behaviors of a casting blank in a continuous casting process through a continuous casting full-flow heat/force coupling model established by taking MSC.Marc as a platform; extracting required data through an MSC.Marc secondary development interface, and comparing and analyzing tensile strain of each node with a critical crack judgment criterion; and finally, obtaining the crack risk coefficient of each node and drawing a crack risk cloud picture.
The application of the method for predicting the crack risk of the continuous casting billet is characterized in that a continuous casting process is optimized through an established crack risk prediction model, the position of the crack can be seen through a crack risk cloud picture, whether the design of a bending and straightening section of a casting machine is reasonable or not and the rolling reduction control in the continuous casting pressing process are regulated and controlled, the risk of the crack is avoided, and the method has great significance for guiding the actual production on site.
A continuous casting blank crack risk prediction method, the middle crack initiation, surface crack propagation are mainly caused by tensile strain or tensile stress in the continuous casting process, therefore the invention chooses tensile strain as the middle crack initiation, surface crack propagation judge basis, the invention, according to the actual casting machine CAD drawing, extracts the corresponding roll row coordinate and diameter, etc. relevant parameter and introduces finite element software, set up the continuous casting whole-flow FEM model from crystallizer meniscus beginning to the end of the air cooling area; and (4) establishing a crack risk prediction model by combining the determined critical crack judgment criterion and the established continuous casting full-process heat/force coupling model.
The invention discloses a method for predicting the crack risk of a continuous casting billet and application thereof, which have the beneficial effects that:
1. according to the invention, the crack risk prediction model is used for analyzing the crack initiation risk in the middle of the bearing steel bloom and the microalloyed steel wide and thick plate blank and the crack propagation risk at the corner of the TiMo microalloyed steel, and the result shows that the reduction of the 1 # withdrawal straightening machine and the 2# withdrawal straightening machine is controlled in a smaller range of 1-2 mm when the bearing steel bloom is produced, the reduction of the 3 # withdrawal straightening machine, the 4# withdrawal straightening machine and the 5# withdrawal straightening machine can be gradually increased, the reduction of the 6 # withdrawal straightening machine and the 7# withdrawal straightening machine is not increased too much compared with that of the 5# withdrawal straightening machine, and the 8 # withdrawal straightening machine and the 9# withdrawal straightening machine can implement larger reduction to improve the loosening and shrinkage cavity so as to improve the central quality of the casting blank; when producing a wide and thick microalloyed steel plate blank, the reduction is controlled to be at a lower level when the solid phase rate is lower, the reduction is properly increased when the solid phase rate is higher, and the casting blank is loosened and shrunk by applying a larger reduction after the solidification end point; when producing the TiMo microalloy steel grade, excessive reduction is avoided to control corner crack defects.
2. The method for predicting the crack risk of the continuous casting billet is suitable for the continuous casting billets with multiple steel types and multiple sections, can predict and analyze the crack risk of the continuous casting billets, and has more visual and accurate results; the continuous casting billet crack risk prediction model can analyze the crack risk of the whole continuous casting process, can also extract the crack risk result at a certain position of a casting flow, and is more flexible, so that the production practice can be guided more conveniently.
3. Compared with the traditional heat/force coupling model with only a pressing area, the continuous casting full-flow heat/force coupling model has the advantages that the bending straightening section and the crystallizer area are added, so that the number of roller arrays is huge, a Marc secondary development function is needed, a Marc-recognized machine language is used for compiling a command stream file and finally directly leading the command stream file into the Marc, the automatic modeling of the casting roller is realized, the modeling time is greatly saved, a plurality of models can be built in a short time, and a plurality of working conditions are analyzed; the continuous casting full-flow heat/force coupling die not only can flexibly control the rolling reduction of each casting roller; the method can also accurately simulate the whole continuous casting process, and particularly realizes the accurate monitoring of the crack highly-developed area at the pressing position of the straightening section, which is not possessed by the traditional model. The heat transfer behavior in the continuous casting process, the interaction of the deformation behavior and the accumulated influence of the deformation can be fully considered, and the analysis of the full-process thermal/mechanical behavior has a guiding function for researching the process formulation of the intermediate crack initiation, the surface crack propagation, the light pressure and the heavy pressure.
Drawings
Fig. 1 is a CAD drawing (for example, a bloom) provided by a steel mill.
FIG. 2 shows a continuous casting full-flow heat/force coupling model.
FIG. 3 is a flow chart of a crack risk cloud map calculation.
FIG. 4 shows a monitoring surface of a casting blank (for example, a bloom).
FIG. 5 is a cloud chart of the risk of median crack in GCr15 bearing steel bloom in example 1 of the present invention.
FIG. 6 is a cloud chart of the risk of median crack of the microalloy wide and thick slab in the example 2 of the invention.
FIG. 7 is a cloud chart of risk of corner crack of TiMo microalloy steel plate blank in example 3 of the invention.
Detailed Description
The present invention will be described in further detail with reference to examples.
A method for predicting crack risk of continuous casting billets is characterized in that a crack risk prediction model is established on the basis of a determined critical crack judgment criterion and an established continuous casting full-flow heat/force coupling model. Specifically, a continuous casting full-flow heat/force coupling model established for a platform through finite element software is used for simulating and analyzing heat transfer and deformation behaviors of a casting blank in a continuous casting process, and required tensile strain, temperature and other data are extracted from a calculation result through a secondary development interface; comparing and analyzing the tensile strain and the critical strain of each node through a crack risk prediction model to obtain a crack risk coefficient of each node and drawing a crack risk cloud picture;
example 1
In the embodiment, GCr15 bearing steel with the cross section size of 410mm multiplied by 530mm is produced by continuous casting, a continuous casting soft reduction technology is adopted in a solid-liquid two-phase region at the solidification end of a continuous casting billet, the casting machine drawing speed is 0.58m/min, the drawing speed is kept stable and unchanged, a node on the middle surface of the casting billet in the casting billet drawing direction is selected as an object, the change condition of the drawing strain at each position on the middle surface along with the position of a casting flow is researched, the monitoring surface is shown in figure 4, when the reduction of No. 1-9 withdrawal straightening machines is 0/1/1/1/2/3/4/4/2mm, the position schematic diagram and the change condition of the drawing strain on the middle surface along with time are analyzed, and a crack risk cloud chart is analyzed.
The method for predicting the crack risk of the continuous casting billet comprises the following steps:
step 1: the critical strain for the initiation of the GCr15 steel median crack is selected as a crack initiation judgment criterion, and the critical strain for the initiation of the GCr15 steel median crack in the embodiment is determined by a high-temperature tensile test, and the value of the critical strain is 0.05.
Step 2, extracting corresponding roll row coordinates and diameters of all rolls of the bearing steel bloom continuous casting machine according to an actual casting machine CAD drawing (shown in figure 1), importing the roll row coordinates and the diameters into MSC.Marc finite element software, establishing a continuous casting full-flow heat/force coupling model (shown in figure 2) from a crystallizer meniscus to the end of an air cooling area in the finite element software, and simulating and analyzing the temperature and deformation simulation results of the bearing steel bloom;
the establishment process comprises the following steps: extracting the geometric information of the roller rows in the CAD drawing of the casting machine, and compiling a command stream file; the Marc secondary development function interface is utilized to read the command stream file to automatically establish the roller array model, the command stream file is adopted to establish the roller array model, the time required by modeling is greatly saved, the programming of the command stream process is realized, and the rapid modeling can be realized for different casting machines; then, dividing a casting blank entity by using a mesh divider; and finally, establishing a continuous casting full-process heat/force coupling model from the meniscus of the crystallizer to the end of the air cooling zone.
And step 3: establishing a crack risk prediction model by combining the critical crack judgment criterion determined in the step 1 and the continuous casting full-process heat/force coupling model (continuous casting full-process FEM model) established in the step 2, carrying out comparative analysis on the tensile strain of each node and the critical crack judgment criterion, wherein a calculation flow chart is shown in figure 3, firstly, the temperature change process of each node on a monitoring plane in the full process and the tensile strain change process of each node are extracted, then, whether each node meets the crack initiation condition in each increment step, namely whether the temperature is in a crack risk temperature interval or not and whether the tensile strain exceeds the crack critical strain or not is judged, if the crack initiation condition is met, the crack risk coefficient of the corresponding position is increased by 1, and finally, the crack risk coefficient of each node is obtained through statistics; and finally, extracting coordinates of each node of the monitoring plane, and drawing a crack risk cloud picture (see fig. 5).
And analyzing the crack initiation risk in the middle of the bearing steel bloom by using the obtained crack risk cloud picture. According to the theory of median crack formation, the conditions for median crack initiation are as follows: the temperature of the casting blank is in a temperature range from ZDT to LIT, and the tensile strain borne by the casting blank exceeds the critical strain for the initiation of the intermediate crack. Therefore, after thermal/force coupling simulation is carried out on each working condition, whether each node meets the condition of middle crack initiation or not is judged one by one in an incremental step mode, then the total incremental step number of each node meeting the condition of middle crack initiation is counted, and the risk of middle crack initiation is represented according to the total incremental step number.
Example 2
In the embodiment, Q345E microalloy steel wide and thick plate blanks with the cross section dimension of 300mm multiplied by 2200mm are continuously cast and produced, the casting machine drawing speed is 0.80m/min, and the drawing speed is kept stable and unchanged;
a method for predicting the crack risk of the continuous casting slab of the embodiment comprises the following steps:
step 1: the critical strain for the initiation of the median crack of the Q345E steel is selected as a crack initiation judgment criterion, and the critical strain for the initiation of the median crack of the Q345E steel in the embodiment is 0.04.
Step 2: introducing the geometric dimensions of each device in the continuous casting process into MSC.
And step 3: establishing a crack prediction model and obtaining a middle crack risk cloud picture based on the critical crack judgment criterion, the temperature and the deformation simulation result of the middle crack initiation of the microalloy steel wide and thick plate blank, and analyzing the middle crack initiation risk according to the middle crack risk cloud picture (see figure 6).
Example 3
In the embodiment, the TiMo microalloyed steel with the cross section size of 200mm multiplied by 1200mm is produced by continuous casting, the casting machine drawing speed is 1.1m/min, the drawing speed is kept stable and unchanged, the crack occurrence rate at the corner position on the surface of a wide and thick slab is high, the influence on the casting blank production is large, and the crack sensitivity is increased by adding microalloy elements. Selecting TiMo microalloyed steel with higher microalloy content as a research object, and analyzing the risk of corner crack propagation by using the TiMo microalloyed steel wide and thick slab corner crack propagation critical criterion, the temperature and deformation simulation result and a crack risk prediction model.
The method for predicting the crack risk of the continuous casting billet comprises the following steps:
step 1: and selecting critical strain of TiMo microalloyed steel wide and thick slab corner crack propagation as a crack propagation judgment criterion.
Step 2: according to the continuous casting process of the TiMo microalloyed steel, the geometric dimension of equipment in the continuous casting process is introduced into finite element software, and a continuous casting full-flow heat/force coupling model starting from a meniscus of a crystallizer to finishing of an air cooling area is established;
and step 3: and (3) establishing a corner crack risk prediction model and obtaining a corner crack propagation risk cloud picture according to the critical crack judgment criterion determined in the step (1) and the continuous casting full-process heat/force coupling model (continuous casting full-process FEM model) established in the step (2), wherein the corner crack propagation risk cloud picture is shown in figure 7.
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| CN110941889B (en) * | 2019-08-29 | 2024-03-22 | 华北理工大学 | Research method for germination and expansion of microscopic and macroscopic cracks of continuous casting special-shaped blank |
| CN112949998A (en) * | 2021-02-04 | 2021-06-11 | 成都鼎安华智慧物联网股份有限公司 | System and method for dynamically constructing regional natural disaster risk cloud picture |
| CN117272761B (en) * | 2023-11-21 | 2024-04-26 | 北京科技大学 | Method and system for monitoring middle cracks of bloom |
| CN117358892B (en) * | 2023-12-05 | 2024-03-08 | 济南东方结晶器有限公司 | Deformation monitoring and early warning method and system for crystallizer copper pipe |
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