关于轧钢轧制力,轧制力矩,轧制能耗,电机功率的相关计算研究整理

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原文引自钢铁人社区公众号:https://mp.weixin.qq.com/s/9QXCuI3--R8zYusFwMZT5A

轧制力:又称轧制压力,是指辊加于轧件使之产生塑性变形的力。但通常把轧件作用于轧辊上（作用力与反作用力）并通过压下螺丝传递给机架的力称为轧制力，即是轧件加于轧辊的反作用力的垂直分量。轧制力在我国习惯称为轧制压力或轧制总压力。

轧制压力是轧制过程的重要工艺参数之一，它不仅为轧机的设计和轧制工艺的制定提供参考依据，其分布也将直接影响到板带的厚度与板形。正确测定和计算轧制力，对于设计和使用轧机有重大意义。

轧制力矩:是为使轧制正常进行，需要施加的克服金属变形抗力和金属同轧辊间的摩擦力的力矩。

为使轧制正常进行，需要施加的克服金属变形抗力和金属同轧辊间的摩擦力的力矩。轧制力矩是确定轧机的主电机和轧辊传动机构负荷的基本参数。

轧制能耗:不仅是一个技术经济指标,也是一个重要的力能参数,在工程上可用来间接确定传动负荷.通常按轧制时的能量消耗确定轧制力矩较容易些,而按轧制压力确定轧制力矩较为困难,这是因为轧制复杂断面型材和板材时,确定接触面积和平均单位轧制压力均比较复杂.因此,采用单位轧制能耗曲线估算轧制力矩得到了广泛的应用.   

在最初阶段，轧钢生产完全是一门手艺，全靠个人经验和生产技艺;后来工业化导致形成了独立的轧钢工业部门。虽然轧制理论有了一定的发展，但主要是以现场或实验室试验研究的经验为依据，以试验法为基本方法;

当前由于计算机在轧钢中的应用，使轧钢生产技术正在向一个崭新的工程科学(engineering science)阶段过渡，这一阶段是以计算机为工具对生产进行过程模拟、系统优化、自动控制与监测，取代传统的试验法,在生产和制造之前使用计算机对生产过程、工艺参数以及结果进行模拟并从整个系统进行优化，实现超前规划和设计，并在生产过程中由计算机进行准确控制和严格监测，这样就使轧钢生产技术向前跨出了一大步，并带来了巨大的经济和社会效益。

以Python语言编程整理轧制力,能耗等相关算法,应用于轧钢的设计,生产,及解决相关问题,更加方便工艺及生产人员辅助使用.现将相关研究共享给大家:

一.初始化系统,输入必要相关参数,建立数据模型列表

"""使用斯米尔诺夫轧制力/力矩计算模型"""

def__init__(self):#初始化

self.kx_m=input("输入孔型号:")self.Dg1=float(input("输入工作辊径:"))#工作直径self.H0=float(input("输入来料高度:"))#来料高度self.B0=float(input("输入来料宽度:"))self.H1=float(input("输入本道次料高/厚度:"))#本架料高self.bk1=float(input("本孔型宽度(或料宽):"))self.v1=float(input("输入轧制线速s/min:"))#线速self.sr=float(input("输入减速机速比:"))#减速机速比self.t1=float(input("输入轧制温度℃:"))#温度msg_as=f"""设置箱形孔侧壁斜度(用a/b的小数形式表示):正常为0.1-0.5(即:10%-50%)平辊请设置为1,注:此参数对其它孔型无效"""self.tanAs=float(input(msg_as+"输入侧壁斜度:"))#孔型侧壁斜度用a/b的小数形式表示.超过1用1代替self.HH=self.H1/self.H0#n压下系数hself.AA=self.Dg1/self.H1#A,A=D/H,轧辊转换直径self.N1=self.v1/3.14159/(self.Dg1/1000)#轧辊转速r/min>>>输入线速算出self.Dj_v1=self.N1*self.sr*60#电机转速self.A0=self.H0/self.B0#轧前轴比,就是高宽比self.Ak=(self.B0*1.18)/self.H1#本孔的宽高比,用B0*1.18预算宽度为模拟值(延伸孔为主)self.Mm=(2*(((self.AA/2)*(1/self.HH-1))**0.5))/(1/self.HH+1)#变形区形状系数(l/Hc)kxlist=[["1","方>>平箱"],["2","平>>方箱"],["3","方>>菱"],["4","菱>>方"],["5","菱>>菱"],["6","椭圆>>方"],["7","方>>椭圆"],["8","六角>>方"],["9","方>>六角"],["10","椭圆>>圆"],["11","圆>>椭圆"],["12","无孔--平"],["13","无孔--方"],["14","圆>>无孔"],["15","方>>平椭圆"],["16","平椭圆>>圆"],["17","型钢成型孔"],["18","型钢切深孔(变形量大)"],["19","型钢控型(腿)孔"]]print("\n孔型系统:")for i in kxlist:print(i[0],i[1])self.KX=int(input("\n输入序号选定孔型系统:"))for j in kxlist:if int(j[0])==self.KX:#孔型系统选择序号kxlb=j#self.KX=kx#孔型系统选择序号self.kxlb=kxlb#孔型系统列表if self.t1>899:self.mcxs=1-(self.t1-900)*(4/3000)#摩擦系数原数据是900度,4/3000.目前低温较多,放大到700度else:self.mcxs=1-(self.t1-900)*(self.self)#摩擦系数原数据是900度,8/3000.目前低温较多,放大到700度self.ysxs=self.H0*self.B0/(self.H1*(self.B0+(self.H0-self.H1)*0.25))["1","20#钢","83","11.6","0.0025","1.79","0.252","0.70","0.14"],["2","Q235","84","11.6","0.0025","1.79","0.252","0.71","0.141"],["3","45#钢","86","11.6","0.0025","1.79","0.252","0.72","0.143"],["4","Q275","90","11.6","0.0025","1.79","0.252","0.72","0.143"],["5","Q345","91","11.6","0.0025","1.79","0.252","0.72","0.143"],["6","HRB400","92","11.6","0.0025","1.79","0.252","0.72","0.143"],["7","40Cr","90","11.6","0.0025","1.79","0.252","0.72","0.143"],["8","GCr15","93","11.6","0.0025","1.79","0.252","0.72","0.143"],["9","16Mn","96","11.6","0.0025","1.79","0.252","0.72","0.143"],["10","12CrNi3A","98.1","17.8","0.0029","1.79","0.252","0.72","0.143"],["11","60Si2","112","17.8","0.0029","1.9","0.28","0.85","0.087"],["12","1Cr13","112.8","17.8","0.0029","1.9","0.28","0.85","0.087"],["13","4Cr13","107","26.6","0.0033","1.9","0.28","0.85","0.087"],["14","Cr17Ni2","110","39","0.0037","1.9","0.28","0.85","0.087"],["15","Cr18Ni19Ti","119.8","16.35","0.0028","1.9","0.28","0.85","0.087"],["16","Cr18Ni12MN2Ti","144.3","16.35","0.0028","1.9","0.28","0.9","0.09"]]print("\n常用钢种：")for k in list:print(k[0],k[1],k[2])gz=int(input("\n输入序号选择钢材成分:"))for l in list:if int(l[0])==gz:self.gzlist=l        

break

二.计算变形抗力值:

def Qs(self):#变形抗力kx=self.KX#变形程度if(kx==1 or kx==6 or kx==8 or kx==2 or kx==12 or kx==13 or kx==16):k_e=(self.H0-self.H1)/self.H0elif(kx==3 or kx==4 or kx==5 or kx==10 or kx==11 or kx==14):k_e=((self.H0-self.H1)/self.H0)*(2/3)elif(kx==7):#7.方>>椭圆cmd1=0.95#float(input("输入椭圆孔充满度(0.9-0.99):"))k_e=1-(self.H1/self.H0)*(1.16-0.20*cmd1)elif(kx==9):#方>>六角#bk=self,bk1#float(input("输入六角孔孔型开口宽度mm:"))BKH=self.bk1/self.H1k_e=1-(self.H1/self.H0)+0.5*(1-((BKH-1)/(1/self.HH)))**2elif(kx==15):#15.方>>平椭圆#bk=float(input("输入平椭圆孔开口宽度mm:"))BKH=self.bk1/self.H1k_e=1-(self.H1/self.H0)+0.5*(1-((BKH-1HH)/(1/self.HH1)))**2else:#其它值调整为主值(与1项同)k_e=(self.H0-self.H1)/self.H0#BKH=self.bk1/self.H1#k_e=1-(self.H1/self.H0)+0.5*(1-((BKH-1)/(1/self.HH)))**2#序号,钢种,Q0基本抗力,A1,m1,A2,m2,A3,m3Ke=float(self.gzlist[5])*(k_e**float(self.gzlist[6]))#孔型影响系数Kt=float(self.gzlist[3])*math.exp(-float(self.gzlist[4])*self.t1)#温度影响系数k_u=0.105*self.N1*((k_e*(self.Dg1/(2*self.H0)))**0.5)#速度影响系数Ku=float(self.gzlist[7])*k_u**float(self.gzlist[8])#速度影响系数qs=float(self.gzlist[2])*Kt*Ke*Ku#变形抗力值计算#print("变形抗力Qs值(MPa):"+str(round(qs,3)))

return qs

三.轧制力矩相关参数计算

def nB(self):#轧制力矩系数"""制力矩系数"""mcxs=self.mcxs#摩擦系数cmd0=0.96#float(input("输入来料孔型的充满度0.9-0.99:"))hh1=1/self.HHkx=self.KXysxs=self.ysxsif(kx==1 or kx==2):#轧制力矩系数计算khao1=hh1*(hh1-1)#原公式前面有-号,去掉了(改值为正)khao2=0.25+((0.0105-0.0012*self.A0**2)/self.tanAs)khao3=(0.254*(1.02-0.2*self.tanAs))/(self.A0+0.1)**2khao4=(0.315+3.425/(self.AA-1))khao5=(1.225-0.18/mcxs)nb=khao1*(khao2-0.024*self.A0**2+khao3)*khao4*khao5elif kx==3:#轧制力矩系数计算nb=((ysxs-1)*(1.6-0.36/mcxs))/(1.6*cmd0-1.11+(0.674-0.540*cmd0)*self.AA)elif kx==4:#轧制力矩系数计算nb=((ysxs-1)*(1.98-0.58/mcxs))/(0.93-12*(0.9-cmd10)**2+(0.648/cmd10-0.56)*self.AA)elif kx==5:#轧制力矩系数计算nb=((self.ysxs-1)*(1.65-0.39/mcxs))/(cmd0-0.4+(0.75-0.625*cmd0)*self.AA)elif kx==6:#轧制力矩系数计算

khao1=0.01+2.30/(self.AA+5)

def nQ(self):#孔型中的应力状态系数"""孔型中的应力状态系数"""mcxs=self.mcxs#摩擦系数cmd0=0.96#float(input("输入来料孔型的充满度0.9-0.99:"))kx=self.KXmm=self.Mmif(kx==1 or kx==2):#箱形孔应力状态系数khao1=mm+37.0/(mm+5)+khao2=0.0488*self.AA+0.534*self.AA/(self.AHA-1)khao3=0.745+0.051/(self.tanAs+0.1)khao4=1.108-0.102*(self.A0**0.5)khao5=1.225-0.18/mcxs

nq=khao1*khao2*khao3*khao4*khao5

#开始计算轧制力数据Pc=1.15*self.Qs()*nq#轧制单位压力Lc=((0.5*self.Dg1)*(self.H0-self.H1))**0.5#轧件轧辊接触弧長Fj=self.bk1*Lc#轧件轧辊接触面积Pz=Pc*Fj#总轧制力

return Pz

四.计算及结果输出:

def run(self):"""轧制力矩计算函数,采用斯米尔诺公式""""""电机功率=总力矩（摩擦力矩+轧制力矩/减速比）*电机转速/传达效率/9.8*1.03"""mom=0.287*self.Qs()*(self.H1**3)*(self.AA**2)*self.nB()/1000000#轧制力矩/kN·mRfpz=self.nQ()/1000#总轧制力/(Kn)Ec=self.Fa_a()*mom*self.v1*3600/self.Dg1#轧制小时能耗Dj_p=(mom*1.2)/self.sr*self.Dj_v1/0.98/9.8*1.03#式中mom*1.2为磨擦系数加功率损耗,
msg=f"""
===========================================
+使用斯米尔诺夫轧制力/力矩计算模型
+孔型:{self.kx_m}.{self.kxlb[1]},孔型侧壁斜度:{round(self.tanAs*100,2)}%
+钢种:{self.gzlist[1]}
+来料宽度{self.B0}mm,来料高度{self.H0}mm,本道次料高{self.H1}mm
+轧制温度{self.t1}℃,轧制速度{self.v1}s/min,工作辊径{self.Dg1}mm
+减速机速比1:{self.sr}电机转速:{str(round(self.Dj_v1,0))}
+变形抗力Qs值:{round(self.Qs(),2)}MPa
+总轧制力:{str(round(Rfpz,2))}kN({str(round(Rfpz/9.8,1))}Tf)
+轧制力矩:{str(round(mom,2))}kN·m
+轧制能耗:{str(round(Ec,2))}Kw
+电机功率:{round(Dj_p,1)}Kw选用电机(60%功)>=:{round(Dj_p/0.6,1)}Kw
注:电机能耗按滚动轴承,齿轮减速箱摩擦系数加功率损耗1.2计算,其它工况另行加减
==========================================="""
print(msg)input("按任意健继续:")

if__name__=="__main__":
for i in range(18):
mom=MOM()

mom.run()

例一:&550轧机用165*165钢坯所计算轧制力,力矩以及电机相关参数结果

例二:&350轧制生产25螺纹钢(单线)计算轧制力,力矩以及电机相关参数结果

,两切分按些数据X2计算.

例三:350轧机生产5#角钢计算轧制力,力矩以及电机相关参数结果.

以上计算数据仅对应相应工况,相关生产工艺数据对结果影响很大,请勿随意对号入座.

如有工艺需求请联系工艺师.

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原文引自钢铁人社区公众号:https://mp.weixin.qq.com/s/9QXCuI3--R8zYusFwMZT5A