| 82 | 0 | 161 |
| 下载次数 | 被引频次 | 阅读次数 |
为提升大型钢锭压实工艺制定的预测能力，结合DEFORM-3D有限元二次开发技术，开发了集成空洞演变模型的压实预测方法，模拟了大钢锭从初始镦粗到径向压下全流程中空洞形态演变与压实工艺的响应过程。通过对不同钢锭初始高径比(H0/D0=1.0～2.0)、空洞初始长短轴比(λ0=1～8)条件下的模拟结果进行分析，揭示了空洞长短轴比和相对体积比等变量随工艺参数的变化规律，建立了“参数计算-约束判定-迭代优化”的空洞压实工艺规划流程。结果表明，径向压下时，空洞初始长短轴比显著影响空洞闭合的临界压下率，λ0=8时的临界压下率低至19.6%,而λ0=1时临界压下率达28.4%。建立的锻造工艺规划方法能够较好地反映大钢锭空洞压实的工艺特性，预测偏差在7%以内，为大钢锭空洞压实工艺规划提供了高效、精准的技术方法。
Abstract：To enhance the predictability in the process planning for compacting large steel ingots, a compaction prediction method integrating void evolution model was developed through the secondary development technology of DEFORM-3D finite element software. The procedure was applied to simulate the evolution of void morphology and the compaction process response throughout the entire process from upsetting to radial compression of large steel ingots. Simulation analyses under various initial height-diameter ratios(H0/D0=1.0-2.0)and initial void aspect ratios(λ0=1-8) of steel ingots were carried out, which revealed the evolution laws of variables including void aspect fraction and relative volume fraction with process parameters.A void compacting process planning procedure based on “parameter calculation, constraint evaluation, and iterative optimization” was established. The results indicate that during radial compression, the initial void aspect ratio significantly affects the critical reduction rate for void closure. When λ0=8, the critical reduction rate is as low as 19.6%, whereas when λ0=1, the critical reduction rate reaches 28.4%. The proposed forging process planning procedure successfully characterizes the void compacting behavior in large steel ingots, with a prediction deviation within 7%, so that it establishes a robust, efficient, and precise method for void compacting process planning.
[1] LIU X,ZHANG C,HU S,et al.Research progress and prospects on the formation mechanism of macrosegregation and shrinkage porosity in large steel ingots[J].Progress in Natural Science:Materials International,2024,34(3):470-481.
[2] CHEN X,Wu B,WU B,et al.Multi-scale analysis of void evolution in large-section plastic mold steel during multi-directional forging[J].Journal of Iron and Steel Research International,2022,29:1961-1977.
[3] XIE J,ZHANG R,LIU T,et al.Growth of random polyhedral void in structural steel based on micromechanical RVE simulations [J].Advances in Engineering Software,2023,175:103344.
[4] 李殿中，马璇，徐斌，等.高效愈合钢锭内部缺陷的锻造工艺设计[J].金属学报，2016,52(10):1199-1206.LI Dianzhong,MA Xuan,XU Bin,et al.Design of forging methods of healing defects in ingots effectively [J].Acta Metallurgica Sinica,2016,52(10):1199-1206.
[5] KIM N,KO D,VANTYNE C,et al.Innovative square cogging to enhance void closure efficiency during forging of continuously cast round blooms[J].International Journal of Material Forming,2022,15(5):63.
[6] JIAO Y,ZHOU C,LIU J,et al.Void evolution behavior and closure criterion inside large shaft forgings during a forging process[J].Materials and Technology,2021,55(3):355-361.
[7] GITSCHEL R,SCHULZE A,TEKKAYA A.Void nucleation,growth and closure in cold forging:An uncoupled modelling approach[J].Advances in Industrial and Manufacturing Engineering,2023,7:100124.
[8] FAVRE A,VALENTE R,OLIVERO D,et al.A study of void closure in hot rolling bars of stainless steel [C]//The 14th International Conference on the Technology of Plasticity.Mandelieu-La Napoule,2024:275-282.
[9] KUKURYK M.Experimental and numerical study of the closure of voids with different size and various locations in the three-dimensional cogging process[J].International Journal of Material Forming,2023,17:1-22.
[10] BUDIANSKY B,HUTCHINSON J W,SLUTSKY S.Void growth and collapse in viscous solids[M].Pergamon:Mechanics of Solids,1982.
[11] ZHANG X X,CUI Z S,CHEN W,et al.A criterion for void closure in large ingots during hot forging[J].Journal of Materials Processing Technology,2009,209:1950-1959.
[12] FENG C,CUI Z.A 3-D model for void evolution in viscous materials under large compressive deformation[J].International Journal of Plasticity,2015,74:192-212.
[13] FENG C,CUI Z,LIU M,et al.Investigation on the void closure efficiency in cogging processes of the large ingot by using a 3-D void evolution model[J].Journal of Materials Processing Technology,2016,237:371-385.
[14] NIU L,ZHANG Q.A void closure model based on hydrostatic integration and the Lode parameter for additive manufacturing AlSi10Mg[J].Journal of Manufacturing Processes,2022,73:235-247.
[15] GEISLER A,SADEGHIFAR M,MORIN J,et al.Void closure during open die forging of large size martensitic stainless-steel ingots:An experimental-analytical-numerical study[J].International Journal of Material Forming,2023,16:1-19.
[16] KIM I,PARK J,KIM J,et al.A generalized void closure model in hot forging process of superalloys[J].Journal of Materials Research and Technology,2025,36:6802-6820.
基本信息:
中图分类号:TG316
引用信息:
[1]王宗洋,冯超,艾海昆,等.基于空洞演变模型的大钢锭压实锻造工艺规划[J].塑性工程学报,2026,33(07):1-10.
基金信息:
国家重点研发计划(2023YFB3405402)
2026-07-20
2026-07-20
2026-07-20