S型截面钢丝辊模拉拔技术研究

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S型截面钢丝辊模拉拔技术研究

摘要

S型截面钢丝是一种异型截面钢丝，在建筑、机械和运输行业有广泛地应用。

目前，异型截面钢丝的生产工艺基本上都是采用以经验为主的试验法制定，产品

质量难以保证。有限元数值模拟技术可以获得具体全面的金属变形过程，已经成

为塑性研究中的有力工具。

论文对 S型截面不锈钢钢丝的成形过程进行研究。根据不锈钢材料强度高、

硬化严重和 S型横截面形状复杂、尺寸小的特点，确定采用两道次辊弯预成形、

两道次辊模拉拔、一道次固模精拉的工艺方案。设计了 S型截面不锈钢钢丝五个

道次成形工艺过程的轧辊孔型。

在CATIA 中建立了轧辊孔型的三维实体模型，利用 DEFORM3D 三维有限元

软件对 S型截面不锈钢钢丝的成形过程进行数值模拟，得到了成形过程中材料的

流动规律、横截面填充性、工件的等效应力场和等效应变场。采用正交试验和数

值模拟相结合的方法，对 S型截面不锈钢钢丝辊模拉拔工艺参数进行优化。选用

残余应力、残余应力极差和损伤系数作为评价指标，分析拉拔速度、摩擦系数和

轧辊直径三个因子对 S型截面不锈钢钢丝的影响。采用极差分析的方法，得到三

个因子对三个工艺参数的敏感程度为摩擦系数>轧辊直径>拉拔速度。从而可以组

合一组最优的工艺参数，即 v=20mm/s，μ=0.15，D=60mm。从对模拟试验结果的

分析中可以得到最优的工艺参数组合使三个评价指标分别下降了 11.75％、9.2％

和45.6％。

关键词：S 型截面钢丝辊模拉拔轧辊孔型极差分析

Research on the Roller Die Drawing of S-Shape Cross

Section Steel Wire

ABSTRACT

S-shape cross-section steel wire is a kind of special cross section steel wire, which

has been widely used in the fields of construction, machinery and transportation because

of its good sealing, excellent corrosion. Then, it always has been produced by empirical-

based test method, and the product quality is difficult to guarantee. It can gain a vivid

and complete metal deformation by finite element simulation, and which has become a

powerful tool for the plastic research.

The processing of S-shape cross-section of stainless steel wire has been researched

in this paper. According to the high strength of stainless steel, complex cross-sectional

shape of S-shape cross section of stainless steel wire and forming method and process

parameters on the impact of wire forming, the method of processing S-shape cross

section of stainless steel wire has been adapted, which is two passes of pre-forming of

cold roll forming, two passes of roller die drawing and one pass of drawing. And pass

system and roller die of five passes have been designed.

S-shape cross-section of stainless steel wire forming process of the finite element

model has been created in CATIA, and DEFORM3D software has been used to simulate

the forming process of S-shape cross-section of stainless steel wire. By the above, we

can gain the results of the flow rule of workpiece material, cross-section shape, the

equivalent stress and equivalent strain, which can improved the roller die design of S-

shape cross-section of stainless steel wire. Orthogonal test and numerical simulation

method have been adapted to optimize the process parameters of roller die drawing of

S-shape cross-section stainless steel wire. Residual stress, residual stress range and

damage coefficient have been evaluation index to analysis effects of drawing speed,

friction coefficient and roll diameter on roller die drawing of S-shape cross-section of

stainless steel wire. Range analysis method used to judge the sensitivity of three factors

to various process parameters of roller die drawing. The order is friction coefficient

>roller die diameter > drawing speed. Then it can obtain a set of optimal combinations

of the parameters, namely, v = 20mm / s, μ = 0.15, D = 60mm. Optimal combinations of

the parameters of the process parameters compared with the initial combination, the

simulation results of three evaluation index decreased by 11.75%, 9.2%, 45.6%.

Ⅱ

Key Words ：S-Shape Cross Section Steel Wire, Roller Die Drawing,

Roller Pass，Range Analysis

III

目 录
摘要....................................................................................................................................I
ABSTRACT.....................................................................................................................II
第一章　绪论...................................................................................................................1
§1.1 课题的来源及意义...........................................................................................1
§1.1.1 课题的来源............................................................................................1
§1.1.2 课题的意义............................................................................................1
§1.2 辊模拉拔国内外发展现状...............................................................................3
§1.2.1 辊模拉拔国外发展现状........................................................................3
§1.2.2 辊模拉拔国内发展现状........................................................................5
§1.3 研究内容和技术路线.......................................................................................5
§1.3.1 研究内容................................................................................................5
§1.3.2 技术路线................................................................................................6
§1.4 本章小结...........................................................................................................6
第二章  S型截面不锈钢钢丝成形工艺和模具设计....................................................7
§2.1 辊模拉拔分析...................................................................................................7
§2.1.1 辊模拉拔受力分析................................................................................7
§2.1.2 辊模拉拔运动学分析............................................................................8
§2.1.3 实现辊模拉拔的基本条件..................................................................10
§2.2 S 型截面不锈钢钢丝加工成形工艺方案......................................................11
§2.2.1 加工工艺..............................................................................................11
§2.2.2 S 型截面不锈钢钢丝各道次形状尺寸...............................................12
§2.3 轧辊模具设计.................................................................................................14
§2.3.1 孔型概述..............................................................................................14
§2.3.2 孔型分类..............................................................................................15
§2.3.4 孔型设计..............................................................................................15
§2.4.5 轧辊的直径和厚度选择......................................................................17
§2.4 本章小结.........................................................................................................18
第三章 弹塑性有限元理论及 DEFORM3D 概述........................................................19
§3.1 弹塑性理论.....................................................................................................19
§3.1.1 屈服准则..............................................................................................19
§3.1.2 硬化法则..............................................................................................20
§3.1.3 流动法则..............................................................................................22
§3.1.4 加载、卸载法则..................................................................................23
§3.1.5 大变形弹塑性本构方程......................................................................23
§3.2 DEFORM3D 概述...........................................................................................24
§3.2.1 DEFORM 简介.....................................................................................24
§3.2.2 接触模型..............................................................................................26
Ⅰ

§3.2.3 摩擦分析..............................................................................................27
§3.3 本章小结.........................................................................................................28
第四章  S型截面不锈钢钢丝成形过程数值模拟......................................................29
§4.1 有限元模型的建立.........................................................................................29
§4.1.1 辊弯预成形有限元模型......................................................................30
§4.1.2 辊模拉拔有限元模型..........................................................................31
§4.2 前处理参数定义.............................................................................................32
§4.2.1 材料定义..............................................................................................32
§4.2.2 运动关系..............................................................................................33
§4.2.3 摩擦定义..............................................................................................33
§4.2.4 边界条件..............................................................................................34
§4.3 本章小结.........................................................................................................34
第五章  S型截面不锈钢钢丝模拟结果分析..............................................................35
§5.1 辊弯数值模拟结果.........................................................................................35
§5.1.1 横截面上网格的变化..........................................................................35
§5.1.2 等效应力和等效应变分布..................................................................36
§5.2 辊模拉拔数值模拟结果.................................................................................40
§5.2.1 第一道次辊模拉拔数值模拟结果......................................................40
§5.2.2 第二道次辊模拉拔数值模拟结果......................................................42
§5.2.3 横截面形状..........................................................................................44
§5.3 辊模拉拔工艺参数组合优化.........................................................................45
§5.3.1 试验设计与试验结果..........................................................................45
§5.3.2 产品横截面形状比较..........................................................................49
§5.3.3 辊模拉拔工艺参数组合方案优化......................................................50
§5.3.4 最优化方案与初始方案的比较..........................................................51
§5.4 本章小结.........................................................................................................53
第六章 结论和展望.......................................................................................................54
§6.1 全文总结.........................................................................................................54
§6.2 研究展望.........................................................................................................55
参考文献.........................................................................................................................56
Ⅱ

第二章绪论

第一章　绪论

§1.1 课题的来源及意义

§1.1.1 课题的来源

近年来，随着我国石化产业、基础设施建设和机械制造行业的快速发展，对

异型截面不锈钢钢丝的需求越来越大，国内异型钢丝的生产企业已经远远不能满

足国内市场对异型截面不锈钢钢丝的需求。因此，开发新的异型截面不锈钢钢丝

的生产加工工艺和生产设备成为很多钢丝生产企业发展生产技术、更新先进设备

的一个良好契机。

本课题是应江苏省太仓市某石化企业的要求，开发应用于大型耐高压储存容

器外层缠绕 S 型截面不锈钢钢丝生产工艺。S 型截面不锈钢钢丝如图 1. 1 所示，

是一种异型截面钢丝，它们一层一层紧密的缠绕在一起，可以提高储存容器的耐

高压性能，同时阻止空气、水分和一些腐蚀物质与物体表面金属层的接触，可以

提高容器的耐腐蚀性，降低物体的维修成本。S 型截面不锈钢钢丝不仅可以用于

耐高压容器的缠绕，也可以用于大型锻压设备的机身缠绕、悬索桥主缆钢丝的缠

绕和飞机舱体的缠绕等。

a. 钢丝截面图 b. 钢丝缠绕原理图

图1.1 S 型截面不锈钢钢丝

Fig. 1.1 S Shape Cross Section Steel Wire

§1.1.2 课题的意义

S型截面不锈钢钢丝是不锈钢钢材中的一个品种，2000 年我国不锈钢钢丝的

消费量仅占不锈钢材消费的5%，而工业发达国家基本上都是 10%以上。近几年

来，我国不锈钢钢丝的年消费量从 12 万吨上升到20 万吨，而且还在不断的增长

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摘要：

S型截面钢丝辊模拉拔技术研究摘要S型截面钢丝是一种异型截面钢丝，在建筑、机械和运输行业有广泛地应用。目前，异型截面钢丝的生产工艺基本上都是采用以经验为主的试验法制定，产品质量难以保证。有限元数值模拟技术可以获得具体全面的金属变形过程，已经成为塑性研究中的有力工具。论文对S型截面不锈钢钢丝的成形过程进行研究。根据不锈钢材料强度高、硬化严重和S型横截面形状复杂、尺寸小的特点，确定采用两道次辊弯预成形、两道次辊模拉拔、一道次固模精拉的工艺方案。设计了S型截面不锈钢钢丝五个道次成形工艺过程的轧辊孔型。在CATIA中建立了轧辊孔型的三维实体模型，利用DEFORM3D三维有限元软件对S型截面不锈钢钢丝的成...

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