Study on the inheritance relationship between billet and rail surface defects
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摘要: 通过在无超标缺陷的铸坯表面的轧制滑移区域和轧制稳定区域分别制作人造缺陷，采用正常的加热、轧制、矫直工艺，并依据轧制延伸系数在钢轨成品对应人造缺陷处取样、打磨，采取涡流探伤仪等无损检测设备分析缺陷形貌，判断铸坯与钢轨成品表面缺陷明显的对应关系。同时，通过分析钢轨缺陷形貌及分布，推断铸坯缺陷的演变规律，拟合铸坯与钢轨成品表面缺陷的继承关系，利用该继承关系成功将钢轨上的缺陷溯源回铸坯上，缺陷溯源形貌对应度高达90%，缺陷溯源定位误差±2‰。可以帮助技术人员快速准确地定位铸坯上的缺陷位置，预估铸坯上的缺陷形貌及产生区域，即时选取合适的应对策略，进行缺陷消除，有效提升钢轨良品率。Abstract: In the test, artificial defects were made in the rolling slip area and rolling stable area on the surface of the casting slab without over standard defects. Normal heating, rolling and straightening processes were adopted, and samples were taken and polished at the corresponding artificial defects of the rail according to the rolling elongation coefficient. Nondestructive testing equipment such as eddy current flaw detector was used to analyze the defect morphology and to evaluate the relationship between the surface defects of the casting slab and the rail. At the same time, the evolution law of slab defects is deduced, and the inheritance relationship between slab and rail surface defects is fitted by analyzing the morphology and distribution of rail defects. The defects on rail are successfully traced back to the slab by using this inheritance relationship. The correspondence of defect tracing morphology is as high as 90%, and the defect tracing positioning error is ±2‰. It can help technicians quickly and accurately locate the defect positions on the slab, predict the defect morphology and initiation area on the slab, select suitable strategies in time to eliminate defects, and effectively improve the yield of rails.
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Key words:
- billet /
- rail /
- surface defects /
- inheritance relationship /
- simulation
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图 1 钢轨表面线纹缺陷
(a) 闭合性线纹缺陷 (不可见) ；(b) 打磨后暴露线纹缺陷； (c )裂纹形貌及脱碳情况；(d) 开放式裂纹缺陷 (外观可见)；(e) 外观暴露线纹缺陷；(f) 裂纹形貌及脱碳情况
Figure 1. Linear defects on rail surface
图 2 典型铸坯缺陷
(a) 缩孔； (b) 表面折叠； (c) 表面纵裂；(d )角度横裂；(e) 划伤；(f) 切割不良
Figure 2. Typical billet defects
图 4 铸坯人工孔槽缺陷分布示意
Figure 4. Distribution diagram of defects in artificial hole and groove of slab
图 5 60 kg/m U75V钢坯和钢轨各部位缺陷对应情况
Figure 5. Corresponding situation of defects at various parts of the 60 kg/m U75V billet and rail
图 6 铸坯—成品缺陷位置对应关系
Figure 6. Corresponding relationship between the casting billet and the rail product defect location
图 7 铸坯—成品表面缺陷继承拟合示意
Figure 7. Schematic diagram of continuous fitting of the surface defects of the billet-finished products
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[1] Tao Gongming, Chen Xiao, Zhu Hualin, et al. Analysis on the evolution law of billet defects during rail rolling[J]. Steel rolling, 2018,35(4):50−53. (陶功明, 陈潇, 朱华林, 等. 钢坯缺陷在钢轨轧制过程中的演变规律分析[J]. 轧钢, 2018,35(4):50−53. doi: 10.13228/j.boyuan.issn1003-9996.20170075Tao Gongming, Chen Xiao, Zhu Hualin, et al. Analysis on the evolution law of billet defects during rail rolling [J]. Steel rolling, 2018, 35 (04): 50-53. doi: 10.13228/j.boyuan.issn1003-9996.20170075 [2] Liu Mingyuan. Study on the evolution law of surface defects of continuous casting slab during round steel rolling[J]. Shandong Metallurgy, 2021,43(2):37−40. (刘明远. 连铸坯表面缺陷在圆钢轧制过程中的演变规律研究[J]. 山东冶金, 2021,43(2):37−40. doi: 10.16727/j.cnki.issn1004-4620.2021.02.020Liu Mingyuan. Study on the evolution law of surface defects of continuous casting slab during round steel rolling [J]. Shandong metallurgy, 2021, 43 (02): 37-40. doi: 10.16727/j.cnki.issn1004-4620.2021.02.020 [3] Zhu Jun. Analysis and treatment of surface defects of heavy rail caused by surface nodulation of water beam cushion block of heating furnace[J]. World Nonferrous Metals, 2017,(9):294−295. (朱军. 加热炉水梁垫块表面结瘤引起的重轨表面缺陷分析及治理[J]. 世界有色金属, 2017,(9):294−295.Zhu Jun. analysis and treatment of surface defects of heavy rail caused by surface nodulation of water beam cushion block of heating furnace [J]. World nonferrous metals, 2017 (09): 294-295. [4] Ren Anchao, Zhou Jianhua, Zhu Min, et al. Simulation test of rail surface crack formation[J]. Journal of Wuhan Institute of Engineering and Technology, 2014,26(2):36−38. (任安超, 周剑华, 朱敏, 等. 钢轨表面裂纹缺陷形成的模拟试验[J]. 武汉工程职业技术学院学报, 2014,26(2):36−38. doi: 10.3969/j.issn.1671-3524.2014.02.010Ren Anchao, Zhou Jianhua, Zhu Min, et al. Simulation test of rail surface crack formation [J]. Journal of Wuhan Institute of engineering and technology, 2014, 26 (02): 36-38. doi: 10.3969/j.issn.1671-3524.2014.02.010 -
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