基于Arrhenius模型的Q195钢热轧过程轧制力预测

Hot-rolling force prediction for Q195 steel based on Arrhenius model

  • 摘要: Q195钢因其良好的塑性、焊接性能与低成本,广泛应用于建筑、机械制造、汽车工业等多个领域。然而,在实际轧制生产过程中,该钢种薄板极易因轧制力分布不均引发边浪等板形缺陷,严重影响板带材的尺寸精度和成品质量。因此,精确表征Q195钢在高温条件下的流变行为,并建立准确预测轧制过程力学响应的高精度模型,对改善轧制工艺、提升产品质量具有重要意义。本文通过在 Gleeble-3800 热模拟试验机上进行的热压缩试验获取了不同温度和应变速率下的应力-应变数据,并采用线性拟合方法构建了双曲正弦Arrhenius本构模型。研究发现,Q195钢的流变应力随着变形温度的升高而减小,随着应变速率的增加而增大,其热变形激活能(Q)约为258.2234 kJ·mol-1。并且通过本构模型和试验结果的应力差建立BP神经网络模型来实现对本构模型的应力补偿,最终得到预测结果与试验结果的平均相对误差为0.729%,相关系数为0.99983。随后,基于所建立的本构模型,开发了适用于ABAQUS软件的VUMAT用户材料子程序,并且基于该用户材料子程序,采用工厂实际轧制工艺参数建立了单道次轧制有限元模型。通过将模拟预测结果与工厂实测数据进行对比,发现轧制力预测值与实测值吻合良好,平均误差为1.239%。预测精度显著优于采用原始Arrhenius本构模型和Johnson-Cook本构模型的预测结果,充分验证了所述建模方法在实际工程应用中的准确性与可靠性。

     

    Abstract: Q195 steel is widely utilized across various industries, including construction, mechanical manufacturing, and automotive production, owing to its favorable plasticity, excellent weldability, and low cost. However, during the actual hot rolling process, thin plates of this grade are highly susceptible to shape defects such as edge waves, primarily caused by non-uniform distribution of rolling forces. These defects significantly compromise the dimensional accuracy of strip materials and the quality of final products. Therefore, accurately characterizing the rheological behavior of Q195 steel under high-temperature conditions and establishing a high-precision model for predicting its mechanical response during rolling are crucial for optimizing the rolling process and improving product quality. In this study, stress–strain data under different temperatures and strain rates were obtained through thermal compression experiments conducted on a Gleeble-3800 thermo-mechanical simulator. A hyperbolic sine-type Arrhenius constitutive model was developed using linear regression analysis. The results indicate that the flow stress of Q195 steel decreases with increasing deformation temperature and increases with rising strain rate. The hot deformation activation energy (Q) was determined to be approximately 258.2234 kJ·mol-1. To further enhance prediction accuracy, a BP neural network model was developed based on the discrepancies between the constitutive model predictions and experimental data, enabling effective stress compensation. The integrated model achieved an average relative error of 0.729% and a correlation coefficient of 0.99983 when compared with experimental results. Subsequently, a VUMAT user-defined material subroutine compatible with ABAQUS was developed based on the improved constitutive model. Using actual industrial rolling parameters, a single-pass hot rolling finite element model was established. Comparison between simulation results and plant-measured data revealed that the predicted rolling forces agreed well with the measured values, yielding an average error of 1.239%. The prediction accuracy surpasses those obtained using the original Arrhenius and Johnson–Cook constitutive models, thereby validating the reliability and engineering applicability of the proposed modeling approach.

     

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