多辊摆辗超大直径圆盘件变形机理及工艺理论研究

With the improvement of the safety level of nuclear power, one of the four key components of nuclear power - the end plate and head of nuclear reactor pressure vessel and high-pressure vessel needs a whole disk member with a diameter of more than 8m. At present, the disc parts with a diameter larger than 8m are fabricated by welding. The project proposed a new plastic forming method - multi-roll tumbling overall forming large diameter disc, and the diameter of 10m, the thickness of 100mm disc as an example, the use of theoretical analysis, finite element method and numerical simulation experiment, research on the multi-roller rotary deformation mechanism and process theory. The specific contents include: Achieve stable rolling mechanics, kinematics models and conditions; The interaction between plastic zone and elastic zone and the change rule of motion, the pressure and speed of multi-roll, the speed and feed speed of multi-roll are related to the size and distribution of deformation zone; Strain during deformation, temperature distribution and evolution, the workpiece fine - micro plastic deformation law; Multi-roller rolling super-large-diameter disk blank, mold design method, and multi-roll swing force, torque, power calculation method. Through the above research, to reveal the deformation mechanism of multi-roll super-large-diameter circular disc, to clarify the forming rules of multi-roll super-large diameter circular disc, and to establish the theory of multi-roller super-large diameter disc plastic forming process theory.

随着核电安全等级的提高，大型核电四大关键部件之一—核反应堆压力容器及高压容器之端板和封头需要直径8m以上的整体圆盘件。目前，制作直径大于8m的圆盘件是通过焊接拼装而成。本项目提出一种新的塑性成形方法—多辊摆辗整体成形超大直径圆盘，并且以直径10m、厚度100mm圆盘为例，利用理论分析、有限元数值模拟与缩比实验相结合的方法，对多辊摆辗变形机理及工艺理论进行研究，具体内容包括：实现稳定摆辗的力学、运动学模型及条件；塑性区与弹性区交互作用和运动变化规律，多辊摆辗压力、转速、进给速度等与变形区大小、分布关系；成形过程中应变、温度分布与演变规律、工件细—微观塑性变形规律；多辊摆辗超大直径圆盘件毛坯、模具设计方法，以及多辊摆辗力、力矩、功率计算方法。通过上述研究，达到揭示多辊摆辗超大直径圆盘变形机制，阐明多辊摆辗超大直径圆盘成形规律，建立多辊摆辗超大直径圆盘塑性成形工艺理论之目的。

本项目面向我国大型核电四大关键部件之一—核反应堆压力容器及高压容器之端板和封头需要直径8m以上的整体圆盘件。针对超大直径金属圆盘的整体成形的制造问题，提出了一种新的塑性成形方法—多辊摆辗整体成形。项目从理论、有限元模型和实验相结合的方法，建立了实现多辊稳定辗压和塑性锻透的力学模型和运动学条件；揭示了金属圆盘多辊摆辗的塑性变形机制；揭示了多辊摆辗宏观变形与微观组织演变之间的关系；建立了系统的多辊摆辗成形工艺理论，实现了超大直径金属圆盘多辊摆辗研制的验证。项目发表论文发表17篇、SCI收录10篇；申请国家发明专利7项、授权5项。培养博士研究生1名，硕士研究生7名。项目研究为我国超大直径金属圆盘件的一体化成形制造技术创新与应用提供了重要基础支撑。