Ring protector press column reduction process parameter optimization method and system based on intensity parameters

Abstract

This invention relates to the field of data analysis and processing technology, specifically including a method and system for optimizing process parameters of a retaining ring press with reduced hydraulic column pressure based on strength parameters. The method includes: collecting and inputting temperature field data and pressure field data based on a high-temperature constitutive model corresponding to the retaining ring billet; constructing a joint optimization loop for parameters through L sets of pressing parameters; and coordinating the control of induction heating and infrared heating indices to converge the equivalent rheological strength parameters of each pass to the target strength range, thereby obtaining the optimal parameter combination. This solves the technical problem in the retaining ring pressing process where hydraulic column parameters and heating system are set independently, and process adjustments rely on empirical functions, easily leading to uneven microstructure and residual stress concentration. It achieves the technical effect of constructing a multi-pass joint optimization loop with equivalent rheological strength parameters as the core, driving the coordinated control of induction heating zone power, infrared radiation intensity, and pressing speed, force, and stroke of each hydraulic column, thereby improving forming consistency and microstructure density.

Description

Technical Field

[0001] This invention relates to the field of data analysis and processing technology, specifically to a method and system for optimizing process parameters of a retaining ring press with reduced column strength based on strength parameters. Background Technology

[0002] As a key load-bearing component of a large generator rotor, the uniformity of mechanical properties and the density of the microstructure of the retaining ring directly determine the safety of the equipment. During the high-temperature deformation process, the retaining ring blank is affected by factors such as uneven heating, friction differences and hydraulic response lag, and the equivalent rheological strength of each region is prone to significant dispersion, resulting in uneven distribution of internal residual stress, fluctuation of microstructure properties, and even cracks or dimensional deviations.

[0003] Currently, the process parameters for retaining ring pressing mostly rely on experience setting or offline simulation, lacking real-time perception and closed-loop control of the actual temperature and pressure fields. The heating system and hydraulic execution system are usually controlled independently, making it difficult to dynamically correct the loading state of each column during the pressing process to ensure the spatial uniformity of rheological strength.

[0004] In summary, the existing technology has technical problems such as the independent setting of hydraulic column parameters and heating system in the retaining ring pressing process, and the reliance on empirical functions for process adjustment, which can easily lead to uneven microstructure and residual stress concentration. Summary of the Invention

[0005] This application provides a method and system for optimizing the process parameters of the retaining ring press column based on strength parameters. It aims to solve the technical problems in the existing retaining ring pressing process where the hydraulic column parameters and heating system are set independently, and the process adjustment relies on empirical functions, which easily leads to uneven microstructure and concentrated residual stress.

[0006] In view of the above problems, the technical solution to achieve the present application is as follows: In a first aspect, this application provides a method for optimizing the process parameters of a retaining ring press with reduced columns based on strength parameters. The method includes: after the retaining ring blank has undergone surface pretreatment, it is placed in a multi-cylinder synchronous hydraulic press, and a temperature sensor array and a pressure sensor array are set up; the single-cylinder pressing speed, single-cylinder pressing force, and single-cylinder stroke position of the K hydraulic columns required for the first pass are determined to obtain a first set of pressing parameters; based on the high-temperature constitutive model corresponding to the retaining ring blank, temperature field data and pressure field data are collected and input in real time; a joint parameter optimization loop is constructed through the first set of pressing parameters, the second set of pressing parameters, and the Lth set of pressing parameters corresponding to the Lth pressing parameter set; and the induction heating index and the infrared heating index are coordinated and controlled to make the equivalent rheological strength parameters of each pass converge to the target strength range, thereby obtaining the optimal parameter combination.

[0007] In a possible implementation, the suppression parameters are updated based on the equivalent rheological intensity parameters of the first suppression parameter set, and a second suppression pass is performed to obtain a second suppression parameter set; the suppression parameters are updated based on the equivalent rheological intensity parameters of the (L-1)th suppression parameter set, and a Lth suppression pass is performed to obtain the Lth suppression parameter set.

[0008] In possible implementations, the induction heating index includes the induction heating zone power, and the infrared heating index includes the regional radiation intensity; before each pass, the temperature distribution uniformity index is determined by the temperature field data collected by the temperature sensor array.

[0009] In a possible implementation, the induction heating zone power of the internal induction heating coil and the regional radiation intensity of the external infrared heater of the mold are adjusted according to the temperature distribution uniformity index, so that the temperature field data at each pass meets the rheological intensity consistency requirement.

[0010] In a possible implementation, during the L-pass pressing process, a pressure sensor array arranged on the working surface of the mold synchronously collects the local contact pressure corresponding to K hydraulic columns; based on the local contact pressure and temperature field data corresponding to the K hydraulic columns, combined with the high-temperature constitutive model of the retaining ring billet, the equivalent rheological intensity distribution parameters of each region are inverted, wherein the equivalent rheological intensity distribution parameters of each region constitute the spatial mapping representation of the equivalent rheological intensity parameters; according to the deviation between the equivalent rheological intensity distribution parameters of each region and the target strength threshold, the next pass is dynamically adjusted, wherein the target strength threshold is the nominal strength value within the target strength range.

[0011] In a possible implementation, the response delay time of the hydraulic system and the dynamic characteristic parameters of each servo proportional valve are obtained; based on the response delay time and dynamic characteristic parameters, the equivalent rheological intensity distribution parameters of each region are time-series compensated to generate correction commands corresponding to K hydraulic columns; and the correction commands are loaded into the servo proportional valve controllers corresponding to the K hydraulic columns respectively.

[0012] In one possible implementation, the L-pass suppression process is used as an outer optimization loop, and inner-layer coordinated control is performed within each pass. At the same time, the convergence condition is that the equivalent rheological intensity parameters of each pass in the outer optimization loop all fall within the target intensity range.

[0013] In a possible implementation, the inner layer collaborative control includes: based on the equivalent rheological intensity distribution parameters of the current pass, synchronously updating the induction heating zone power and the single-cylinder pressing speed, single-cylinder pressing force, and single-cylinder stroke position of the K hydraulic columns.

[0014] In one possible implementation, after L passes of pressing are completed, the residual stress distribution of the key section of the retaining ring is collected by an ultrasonic residual stress detection unit; the intensity uniformity of the residual stress distribution is inverted and fed back to the parameter joint optimization loop for initial value optimization.

[0015] In a second aspect, this application provides a system for optimizing process parameters of a retaining ring press with reduced columns based on strength parameters. The system includes: a sensor array setting module: after the retaining ring blank has undergone surface pretreatment, it is placed in a multi-cylinder synchronous hydraulic press, and a temperature sensor array and a pressure sensor array are set; a first pressing parameter set acquisition module: determining the single-cylinder pressing speed, single-cylinder pressing force, and single-cylinder stroke position of the K hydraulic columns required for the first pass, thus obtaining a first pressing parameter set; and an optimal parameter combination acquisition module: based on the high-temperature constitutive model corresponding to the retaining ring blank, real-time acquisition and input of temperature field data and pressure field data, constructing a joint parameter optimization loop through the first pressing parameter set, the second pressing parameter set, and the L pressing parameter sets corresponding to the Lth pressing parameter set, and coordinating the control of induction heating and infrared heating indices, so that the equivalent rheological strength parameters of each pass converge to the target strength range, thereby obtaining the optimal parameter combination.

[0016] In summary, one or more technical solutions provided in this application achieve the technical effect of constructing a multi-pass joint optimization cycle with equivalent rheological strength parameters as the core, driving the coordinated control of induction heating zone power, infrared radiation intensity and the pressing speed, force and stroke of each hydraulic column, thereby improving the consistency of forming and the density of the structure. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are merely exemplary. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0018] Figure 1 This application provides a flowchart illustrating the optimization method for reducing the column process parameters of the retaining ring press based on strength parameters.

[0019] Figure 2 This application provides a structural schematic diagram of a system for optimizing process parameters of a retaining ring press column reduction based on strength parameters.

[0020] Explanation of reference numerals in the attached diagram: Sensor array setting module M100, first suppression parameter set acquisition module M200, optimal parameter combination acquisition module M300. Detailed Implementation

[0021] The technical solutions of this application will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. It should be understood that this application is not limited to the exemplary embodiments described herein. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application. It should also be noted that, for ease of description, only the parts related to this application are shown in the accompanying drawings, not all of them.

[0022] Example 1: The present application will be described in detail below with reference to the accompanying drawings, as follows... Figure 1 As shown, this application provides a method for optimizing process parameters of a retaining ring press with reduced column size based on strength parameters, wherein the method includes: S1: After the surface pretreatment of the retaining ring blank is completed, it is placed in a multi-cylinder synchronous hydraulic press, and a temperature sensor array and a pressure sensor array are set up; S2: Determine the single-cylinder pressing speed, single-cylinder pressing force and single-cylinder stroke position of the K hydraulic columns required for the first pass, and obtain the first pressing parameter set.

[0023] Specifically, surface pretreatment refers to a series of preparatory processes performed on the retaining ring blank before it enters the formal pressing process. These include removing oxide scale, applying high-temperature lubricant, and surface quality inspection, aiming to reduce the forming friction coefficient, prevent surface crack initiation, and ensure effective thermal contact between the sensor and the blank surface. The multi-cylinder synchronous hydraulic press is the core equipment for retaining ring forming, typically configured with 8-16 hydraulic columns evenly distributed along the circumference. A closed-loop synchronous control of multi-cylinder displacement and force is achieved through an electro-hydraulic servo system, with the column spacing determined according to the retaining ring diameter. The temperature sensor array refers to infrared radiation thermometers or K-type thermometers arranged at multiple points along the mold cavity surface and the outer circumference of the blank. / N-type thermocouple arrays, with a spatial resolution typically of 50mm-100mm, are used to capture the circumferential and axial temperature gradients of the billet; pressure sensor arrays are embedded in the working surface of the mold or the end of the hydraulic column piston rod, using piezoelectric or strain gauge sensors to monitor the local contact state between each column and the billet; single-cylinder pressing speed refers to the downward speed of a single hydraulic column piston rod, single-cylinder pressing force is the axial force applied by the column, and single-cylinder stroke position is the displacement of the piston rod relative to the initial zero position; single-cylinder pressing speed, single-cylinder pressing force, and single-cylinder stroke position together constitute the first pressing parameter set, serving as the initial iteration benchmark for multi-pass optimization.

[0024] S3: Based on the high-temperature constitutive model corresponding to the retaining ring blank, temperature field data and pressure field data are collected and input in real time. The L pressing parameter sets corresponding to the first pressing parameter set, the second pressing parameter set to the Lth pressing parameter set are used to construct a parameter joint optimization loop. The induction heating index and infrared heating index are coordinated and controlled so that the equivalent rheological strength parameters of each pass converge to the target strength range, and the optimal parameter combination is obtained.

[0025] Specifically, the high-temperature constitutive model characterizes the flow stress behavior of the retaining ring billet under high temperature (900-1200℃), large strain (ε>0.5), and wide strain rate range, and adopts the Norton-Hoff viscoplastic model to describe the steady-state rheological stage; the parameter joint optimization loop is a two-layer nested optimization architecture: the outer loop traverses from the 1st to the Lth pass, using the result of the inner layer's coordinated control as the initial input for the next pass; the inner loop iterates in real time within a single pass, synchronously updating thermal and mechanical parameters; the induction heating index mainly refers to the zoned power distribution of medium-frequency induction heating, which is achieved by adjusting each induction coil. The current amplitude and phase of the coil enable circumferential temperature control of the billet; the infrared heating index refers to the regional radiation intensity of the quartz tube radiation heater arranged on the outer wall of the mold, which is used to compensate for the temperature drop of the mold and the axial temperature gradient of the billet; the equivalent rheological strength parameter is not a single-point stress value, but a spatial distribution characterization of the equivalent flow stress in each region based on the temperature field-pressure field-constitutive model inversion, comprehensively considering local temperature, strain rate and cumulative strain history; the target strength range is an optimization constraint set according to the material dynamic recrystallization kinetics and microstructure uniformity requirements, and convergence means that the standard deviation of the inverted strength parameters in each pass is less than the threshold and the mean falls into the target range.

[0026] Furthermore, by constructing a joint parameter optimization loop using the L suppression parameter sets corresponding to the first suppression parameter set, the second suppression parameter set, up to the Lth suppression parameter set, the method of this application also includes: The suppression parameters are updated based on the equivalent rheological intensity parameters of the first suppression parameter set, and the second suppression is performed to obtain the second suppression parameter set; the suppression parameters are updated based on the equivalent rheological intensity parameters of the (L-1)th suppression parameter set, and the Lth suppression is performed to obtain the Lth suppression parameter set.

[0027] Specifically, the equivalent rheological strength parameter update refers to the process of using the deviation between the equivalent rheological strength distribution of each region obtained from the previous inversion and the target strength threshold as input, and calculating the parameter correction amount of each hydraulic column and heating system in the next pass through a preset mapping algorithm or optimization solver. The update is not a simple replacement, but an incremental adjustment based on closed-loop feedback. The core is to establish a sensitivity matrix of strength deviation-parameter correction. The pressing parameters refer to the set of triplets of single-cylinder pressing speed, single-cylinder pressing force, and single-cylinder stroke position. Their update must meet the physical constraints of the hydraulic system and the requirements of process continuity. Furthermore, the pressing amount between passes should be smoothly transitioned to avoid abrupt changes that could lead to surface folding. The second pressing parameter set and the Lth pressing parameter set correspond to the complete parameter configuration of the 2nd pass and the Lth pass, respectively. Here, L is the preset total number of passes. The Lth pass is the final pass, and its parameter update needs to additionally consider the convergence of forming size accuracy and surface quality requirements, rather than just the single target of strength. Executing the Lth pressing pass means that after this step is completed, the retaining ring blank reaches the target geometric dimensions and microstructure, and will then enter the cooling and heat treatment process.

[0028] Furthermore, the method of this application includes: The induction heating index includes the induction heating zone power, and the infrared heating index includes the regional radiation intensity; before each pass, the temperature distribution uniformity index is determined by collecting temperature field data through a temperature sensor array.

[0029] Specifically, the induction heating zone power refers to dividing the circumference of the billet into M independent control zones in a multi-coil induction heating system. Typically, M=K or M=K / 2, meaning each of the 1-2 hydraulic columns corresponds to one induction heating zone. Each zone is equipped with an independent intermediate frequency power supply. By adjusting the inverter's output current amplitude and phase angle, targeted heat input to a specific sector area is achieved. The matching design between the number of zones and the number of hydraulic columns determines the spatial resolution of the thermo-mechanical coupling control. Zone radiation intensity refers to the N independent radiation zones divided by the infrared heater along the axial height direction of the billet, with each zone equipped with a quartz halogen tube or silicon carbide rod for radiation. The power density of the radiation source is adjusted by a thyristor power regulator, with the wavelength concentrated in the range of 2μm-4μm to match the absorption characteristics of the metal surface. The regional radiation intensity is mainly used to compensate for the temperature drop of the mold and the axial temperature gradient of the billet. The temperature distribution uniformity index is a comprehensive index that quantitatively evaluates the spatial dispersion of the temperature field of the billet. It is a weighted index based on process requirements, such as giving higher weight to the critical height area of ​​the retaining ring. The temperature distribution uniformity index is calculated based on real-time data collected by the temperature sensor array. Typically, data is collected for a period of time during the stabilization stage before each pressing pass, and the average temperature is taken to eliminate fluctuations, serving as the basis for subsequent heating parameter adjustments.

[0030] Furthermore, the method of this application also includes the coordinated control of induction heating and infrared heating indicators: Based on the temperature distribution uniformity index, adjust the induction heating zone power of the internal induction heating coil and the regional radiation intensity of the external infrared heater of the mold, so that the temperature field data at each pass meets the rheological intensity consistency requirements.

[0031] Specifically, the internal induction heating coil refers to the medium-frequency induction heating device embedded in the inner hole of the retaining ring billet. It is usually composed of a multi-turn spiral coil or segmented sector coil made of water-cooled copper tube. The outer diameter of the coil maintains a 15mm-30mm air gap with the inner diameter of the billet, and the operating frequency is 150Hz-1000Hz. The zone power adjustment adjusts the output current of each coil through an independent medium-frequency power supply to achieve differentiated heat input in different sector areas of the billet circumference. The external infrared heaters of the mold are arranged on the outer circumference and end face of the upper and lower molds. Modular quartz tube radiators or ceramic radiating plates are used, with each module having a power of 5-15kW. They are arranged in layers along the axial direction and the power can be steplessly adjusted from 0-100% through a thyristor power regulator or PWM modulation. The regional radiation intensity adjustment changes the radiation power density of a specific axial height area to compensate for the axial heat loss of the billet in the mold contact area. The rheological strength consistency requirement means that after temperature field control, the equivalent rheological strength difference in each area of ​​the billet caused by temperature homogenization is controlled within the allowable range. This requirement is derived from the temperature sensitivity coefficient of the material's high-temperature constitutive model.

[0032] Furthermore, the method of this application includes: During the L-pass pressing process, the local contact pressure corresponding to K hydraulic columns is synchronously collected by a pressure sensor array arranged on the working surface of the mold. Based on the local contact pressure and temperature field data corresponding to the K hydraulic columns, and combined with the high-temperature constitutive model of the retaining ring billet, the equivalent rheological intensity distribution parameters of each region are inverted. The equivalent rheological intensity distribution parameters of each region constitute the spatial mapping representation of the equivalent rheological intensity parameters. According to the deviation between the equivalent rheological intensity distribution parameters of each region and the target strength threshold, the next pass is dynamically adjusted. The target strength threshold is the nominal strength value within the target strength range.

[0033] Specifically, the pressure sensor array on the working surface of the mold refers to a network of piezoelectric or thin-film strain sensors embedded in the contact surfaces of the upper and lower molds and the retaining ring blank. Typically, 2-4 measuring points are arranged in the sector area corresponding to each column, with 1-2 points each at the inner and outer diameter positions. When K=12 columns, there are a total of 24-48 pressure measuring points, covering a range of 0-250MPa contact pressure, used to capture the spatial distribution of local deformation resistance of the blank. Local contact pressure is the distributed force transmitted from the hydraulic column load to the surface of the blank through the mold. The equivalent rheological intensity distribution parameter is not the intrinsic static yield strength of the material, but the apparent flow stress field dynamically inverted by a high-temperature constitutive model based on real-time temperature, strain rate, cumulative strain and current stress state. Its physical meaning is the ability of each region of the blank to resist continued plastic deformation under the current thermal-mechanical-deformation history.

[0034] Spatial mapping characterization refers to reconstructing a continuous spatial distribution field from discrete K columns corresponding to circumferential sector partitions and axial multi-layer measurement point data through bilinear interpolation or finite element shape function mapping, forming a digital twin image of equivalent rheological intensity; the target intensity threshold is the nominal set value of the target intensity range, usually taken as the midpoint of the range of 90MPa or offset according to the tissue performance requirements, as the benchmark for deviation calculation; dynamic adjustment of the next pass refers to using the intensity deviation inverted from the previous pass as input, and generating the complete parameter set of the next pass through optimization algorithms to realize closed-loop iteration of measurement, inversion, decision-making, and execution.

[0035] Furthermore, based on the deviation between the equivalent rheological intensity distribution parameters of each region and the target intensity threshold, the next pass is dynamically adjusted. The method of this application includes: The response delay time of the hydraulic system and the dynamic characteristic parameters of each servo proportional valve are obtained; based on the response delay time and dynamic characteristic parameters, the equivalent rheological intensity distribution parameters of each region are compensated for in a time sequence to generate correction commands corresponding to K hydraulic columns; the correction commands are loaded into the servo proportional valve controllers corresponding to the K hydraulic columns respectively.

[0036] Specifically, the response delay time of a hydraulic system refers to the pure time lag between the issuance of a control command and the observable response of the hydraulic actuator. It is composed of the signal transmission delay, the valve core movement delay of the servo proportional valve, and the pressure wave propagation delay caused by the compressibility of the hydraulic oil. The total response delay of a large retaining ring press is typically in the range of 50-150ms. The dynamic characteristic parameters of the servo proportional valve describe the valve core's responsiveness to the control signal. Key indicators include bandwidth, step response time, and valve core speed saturation characteristics. Timing compensation, based on a calibrated delay time and dynamic model, sends a corrected command waveform in advance, ensuring that the column movement and the material rheological intensity evolution are synchronized at the actual execution time after considering the delay. This is often implemented using a Smith predictor or a feedforward-feedback composite control structure. The corrected command is not a simple target value setting, but a timing sequence of control signals processed by a dynamic compensation algorithm, such as advancing the speed that should be reached at time t to... It is always issued in the form of steps or ramps. To delay the time, a pre-distortion waveform based on the valve's dynamic characteristics is superimposed, such as adding a leading phase to address the valve's inertial lag; the servo proportional valve controller is the terminal execution control unit of the hydraulic column, receiving ±10V or 4-20mA analog commands or digital bus signals, and adjusting the valve core displacement by driving the proportional electromagnet through PWM, thereby controlling the flow rate and pressure of the oil entering the column cylinder, and realizing closed-loop regulation of pressing speed and pressing force.

[0037] Furthermore, by constructing a joint parameter optimization loop using the L suppression parameter sets corresponding to the first suppression parameter set, the second suppression parameter set, and the Lth suppression parameter set, the method of this application includes: The L-pass suppression process is used as the outer optimization loop, and inner-layer coordinated regulation is performed in each pass. At the same time, the convergence condition is that the equivalent rheological intensity parameters of each pass in the outer optimization loop all fall within the target intensity range.

[0038] Specifically, the outer-layer optimization loop refers to a macroscopic iterative framework that optimizes a complete multi-pass pressing process. Its decision variables are the sequence of pressing parameters for L passes, including K column speeds, forces, strokes, and heating parameters for the L passes. The objective function of the outer-layer loop is the comprehensive performance index of the final state of the process, and the constraints include equipment capacity limitations and material deformation limits for each pass. The inner-layer collaborative control is a microscopic real-time control loop that operates during the execution of a single pass. Its timescale is from milliseconds to seconds. Based on the real-time temperature and pressure field data collected within the pass, the execution parameters of the current pass are further dynamically adjusted to make the rheological intensity evolution trajectory within the pass as close as possible to the preset path. Falling into the target intensity range is the hard convergence criterion of the outer-layer loop. It requires that for all passes and all regions, the equivalent rheological intensity obtained by inversion must meet the target intensity range, rather than only the final pass. This ensures that the deformation of each pass is within the optimal process window and avoids the accumulation of strength anomalies in the early passes that are difficult to correct in the later stages.

[0039] Furthermore, the method of this application includes: The inner layer collaborative control includes: based on the equivalent rheological intensity distribution parameters of the current pass, synchronously updating the power of the induction heating zone and the single-cylinder pressing speed, single-cylinder pressing force and single-cylinder stroke position of the K hydraulic columns.

[0040] Specifically, synchronous updates refer to the parallel calculation and simultaneous issuance of multiple control commands to the induction heating system and hydraulic system within a single control cycle, based on the currently inverted equivalent rheological intensity distribution parameters, rather than the traditional serial mode of adjusting temperature first and then pressure or adjusting independently in stages. This mechanism requires the thermal control system and hydraulic servo system to share a real-time data bus to achieve millisecond-level clock synchronization. The update of the induction heating zone power involves refreshing the power setpoint of the intermediate frequency inverter and possible frequency fine-tuning. In response to changes in the through-heating depth of the billet, such as appropriately increasing the frequency when the temperature rises to maintain the skin effect depth.

[0041] The synchronous updating of single-cylinder pressing speed, single-cylinder pressing force, and single-cylinder stroke position is a three-degree-of-freedom coupled problem in hydraulic control: speed determines strain rate, force determines deformation penetration depth, and stroke determines geometric forming progress. The three are coupled through the pressure-flow characteristics of the hydraulic system. In constant pressure mode, speed fluctuates with load, and in constant speed mode, pressure adapts to material resistance. Stroke serves as the integral constraint of the position closed loop. The inner-layer control needs to decouple the updating strategies of these three based on the strength distribution characteristics. Typically, a hierarchical control structure with speed priority, force limiting protection, and stroke planning constraints is adopted.

[0042] Furthermore, the method of this application also includes: After L passes of pressing are completed, the residual stress distribution of the key section of the retaining ring is collected by the ultrasonic residual stress detection unit; the intensity uniformity of the residual stress distribution is inverted and fed back to the parameter joint optimization loop for initial value optimization.

[0043] Specifically, the ultrasonic residual stress detection unit is a non-destructive testing device based on the acoustoelastic effect. It utilizes the characteristic that the propagation speed of ultrasonic waves in materials changes with the stress state. The rate of change of longitudinal wave velocity is proportional to the stress, and the proportionality coefficient is the acoustoelastic coefficient. By measuring the propagation time difference of the critical refracted longitudinal wave or volume wave, the residual stress distribution on the surface and near the surface is inverted. It is usually composed of an ultrasonic transducer array, a pulse transmitter / receiver, and a mechanical scanning device. The critical section refers to the characteristic parts of the retaining ring with high stress concentration risk and significant impact on safety during service, including: the outer circular surface, the inner hole surface, the end face, and the middle of the wall thickness. The middle section in the height direction and one section on each of the upper and lower end faces are selected as the detection objects.

[0044] The residual stress distribution inversion strength uniformity is an inverse mapping algorithm: based on the detected residual stress field, combined with the material's elastoplastic constitutive relationship and unloading path analysis, the equivalent plastic strain history and rheological strength evolution trajectory experienced by each region during the forming process are calculated, thereby evaluating the actual uniformity of strength control during the process; high residual stress areas usually correspond to areas with insufficient strength control and local over-deformation in the process, while compressive stress concentration areas may correspond to areas with excessive strength and insufficient deformation; feedback to parameter joint optimization cycle refers to using the actual quality data after L passes of pressing as the basis for the initial condition correction of the new round of outer layer optimization cycle, rather than just as a pass / fail criterion; initial value optimization specifically refers to the data-driven correction of the first pressing parameter set of the next process iteration, including: the initial setting value of column speed / force, the pre-allocation of induction heating power, and the target threshold of temperature distribution uniformity index, etc., so that the initial parameters are closer to the optimal solution and the number of outer layer iterations is reduced.

[0045] In summary, the beneficial effects of the embodiments of this application are: By employing a method and system for optimizing the process parameters of a retaining ring press by placing the pre-treated retaining ring blank in a multi-cylinder synchronous hydraulic press and setting up temperature and pressure sensor arrays, the first pressing parameter set is obtained by determining the single-cylinder pressing speed, single-cylinder pressing force, and single-cylinder stroke position of the K hydraulic columns required for the first pass. Based on the high-temperature constitutive model corresponding to the retaining ring blank, temperature field data and pressure field data are collected and input in real time. A joint optimization loop of parameters is constructed through the first pressing parameter set, the second pressing parameter set, and the L pressing parameter sets corresponding to the Lth pressing parameter set. The induction heating index and infrared heating index are coordinated and controlled to make the equivalent rheological strength parameters of each pass converge to the target strength range, thereby obtaining the optimal parameter combination. This application provides a method and system for optimizing the process parameters of a retaining ring press by reducing the number of hydraulic columns based on strength parameters. It realizes the construction of a multi-pass joint optimization loop with equivalent rheological strength parameters as the core, drives the coordinated control of induction heating zone power, infrared radiation intensity, and the pressing speed, force, and stroke of each hydraulic column, and improves the technical effect of forming consistency and microstructure density.

[0046] Example 2 is based on the same inventive concept as the method for optimizing the process parameters of the retaining ring press based on strength parameters in the previous examples, such as... Figure 2 As shown in the embodiment of this application, a system for optimizing process parameters of a retaining ring press column reduction based on strength parameters is provided, wherein the system includes: Sensor array setting module M100: After the surface pretreatment of the retaining ring blank is completed, it is placed in a multi-cylinder synchronous hydraulic press and a temperature sensor array and a pressure sensor array are set.

[0047] The first pressing parameter set acquisition module M200: determines the single-cylinder pressing speed, single-cylinder pressing force, and single-cylinder stroke position of the K hydraulic columns required for the first pass, and obtains the first pressing parameter set.

[0048] The optimal parameter combination acquisition module M300: Based on the high-temperature constitutive model corresponding to the retaining ring billet, it collects and inputs temperature field data and pressure field data in real time. It constructs a parameter joint optimization loop through the L pressing parameter sets corresponding to the first pressing parameter set, the second pressing parameter set to the Lth pressing parameter set, and coordinates the control of induction heating index and infrared heating index to make the equivalent rheological strength parameters of each pass converge to the target strength range, thereby obtaining the optimal parameter combination.

[0049] Furthermore, the optimal parameter combination acquisition module M300 is also used to perform the following method: The suppression parameters are updated based on the equivalent rheological intensity parameters of the first suppression parameter set, and the second suppression is performed to obtain the second suppression parameter set; the suppression parameters are updated based on the equivalent rheological intensity parameters of the (L-1)th suppression parameter set, and the Lth suppression is performed to obtain the Lth suppression parameter set.

[0050] Furthermore, the optimal parameter combination acquisition module M300 is also used to perform the following method: The induction heating index includes the induction heating zone power, and the infrared heating index includes the regional radiation intensity; before each pass, the temperature distribution uniformity index is determined by collecting temperature field data through a temperature sensor array.

[0051] Furthermore, the optimal parameter combination acquisition module M300 is also used to perform the following method: Based on the temperature distribution uniformity index, adjust the induction heating zone power of the internal induction heating coil and the regional radiation intensity of the external infrared heater of the mold, so that the temperature field data at each pass meets the rheological intensity consistency requirements.

[0052] Furthermore, the system for optimizing the process parameters of the retaining ring press column reduction based on strength parameters is also used to perform the following method: During the L-pass pressing process, the local contact pressure corresponding to K hydraulic columns is synchronously collected by a pressure sensor array arranged on the working surface of the mold. Based on the local contact pressure and temperature field data corresponding to the K hydraulic columns, and combined with the high-temperature constitutive model of the retaining ring billet, the equivalent rheological intensity distribution parameters of each region are inverted. The equivalent rheological intensity distribution parameters of each region constitute the spatial mapping representation of the equivalent rheological intensity parameters. According to the deviation between the equivalent rheological intensity distribution parameters of each region and the target strength threshold, the next pass is dynamically adjusted. The target strength threshold is the nominal strength value within the target strength range.

[0053] Furthermore, the system for optimizing the process parameters of the retaining ring press column reduction based on strength parameters is also used to perform the following method: The response delay time of the hydraulic system and the dynamic characteristic parameters of each servo proportional valve are obtained; based on the response delay time and dynamic characteristic parameters, the equivalent rheological intensity distribution parameters of each region are compensated for in a time sequence to generate correction commands corresponding to K hydraulic columns; the correction commands are loaded into the servo proportional valve controllers corresponding to the K hydraulic columns respectively.

[0054] Furthermore, the system for optimizing the process parameters of the retaining ring press column reduction based on strength parameters is also used to perform the following method: The L-pass suppression process is used as the outer optimization loop, and inner-layer coordinated regulation is performed in each pass. At the same time, the convergence condition is that the equivalent rheological intensity parameters of each pass in the outer optimization loop all fall within the target intensity range.

[0055] Furthermore, the system for optimizing the process parameters of the retaining ring press column reduction based on strength parameters is also used to perform the following method: The inner layer collaborative control includes: based on the equivalent rheological intensity distribution parameters of the current pass, synchronously updating the power of the induction heating zone and the single-cylinder pressing speed, single-cylinder pressing force and single-cylinder stroke position of the K hydraulic columns.

[0056] Furthermore, the system for optimizing the process parameters of the retaining ring press column reduction based on strength parameters is also used to perform the following method: After L passes of pressing are completed, the residual stress distribution of the key section of the retaining ring is collected by the ultrasonic residual stress detection unit; the intensity uniformity of the residual stress distribution is inverted and fed back to the parameter joint optimization loop for initial value optimization.

[0057] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on its differences from other embodiments. Figure 1 The optimization method and specific examples of the retaining ring press column reduction process parameters based on strength parameters in Example 1 are also applicable to the retaining ring press column reduction process parameter optimization system based on strength parameters in this embodiment. Through the foregoing detailed description of the retaining ring press column reduction process parameter optimization method based on strength parameters, those skilled in the art can clearly understand the retaining ring press column reduction process parameter optimization system based on strength parameters in this embodiment. Therefore, for the sake of brevity, it will not be described in detail here.

[0058] The above description of the disclosed embodiments enables those skilled in the art to make or use this application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of this application. Therefore, this application is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

[0059] Obviously, those skilled in the art can make various modifications and variations to this application without departing from the spirit and scope of this application. Therefore, if such modifications and variations fall within the scope of this application and its equivalents, this application also intends to include such modifications and variations.

Claims

1. A method for optimizing process parameters of a retaining ring press with reduced column based on strength parameters, characterized in that, The method includes: After the surface pretreatment of the retaining ring blank is completed, it is placed in a multi-cylinder synchronous hydraulic press and equipped with temperature sensor array and pressure sensor array. Determine the single-cylinder pressing speed, single-cylinder pressing force, and single-cylinder stroke position of the K hydraulic columns required for the first pass to obtain the first pressing parameter set; Based on the high-temperature constitutive model corresponding to the retaining ring blank, temperature field data and pressure field data are collected and input in real time. A parameter joint optimization loop is constructed through the L pressing parameter sets corresponding to the first pressing parameter set, the second pressing parameter set to the Lth pressing parameter set. The induction heating index and infrared heating index are coordinated and controlled so that the equivalent rheological strength parameters of each pass converge to the target strength range, and the optimal parameter combination is obtained.

2. The method for optimizing the process parameters of the retaining ring press column reduction based on strength parameters as described in claim 1, characterized in that, The method further includes constructing a joint parameter optimization loop using L suppression parameter sets corresponding to the first suppression parameter set, the second suppression parameter set, and the Lth suppression parameter set. The suppression parameters are updated based on the equivalent rheological intensity parameters of the first suppression parameter set, and the second suppression is performed to obtain the second suppression parameter set. The suppression parameters are updated based on the equivalent rheological intensity parameters of the L-1 suppression parameter set, and the Lth suppression pass is performed to obtain the Lth suppression parameter set.

3. The method for optimizing the process parameters of the retaining ring press column reduction based on strength parameters as described in claim 2, characterized in that, The induction heating index includes the induction heating zone power, and the infrared heating index includes the regional radiation intensity. Before each pass, the temperature field data collected by the temperature sensor array is used to determine the temperature distribution uniformity index.

4. The method for optimizing the process parameters of the retaining ring press column reduction based on strength parameters as described in claim 3, characterized in that, The method further includes: coordinating the regulation of induction heating and infrared heating indicators. Based on the temperature distribution uniformity index, adjust the induction heating zone power of the internal induction heating coil and the regional radiation intensity of the external infrared heater of the mold, so that the temperature field data at each pass meets the rheological intensity consistency requirements.

5. The method for optimizing the process parameters of the retaining ring press column reduction based on strength parameters as described in claim 1, characterized in that, During the L-pass pressing process, the local contact pressure corresponding to K hydraulic columns is synchronously collected by a pressure sensor array arranged on the working surface of the mold. Based on the local contact pressure and temperature field data corresponding to the K hydraulic columns, and combined with the high-temperature constitutive model of the retaining ring blank, the equivalent rheological intensity distribution parameters of each region are inverted, wherein the equivalent rheological intensity distribution parameters of each region constitute the spatial mapping representation of the equivalent rheological intensity parameters. The next pass is dynamically adjusted based on the deviation between the equivalent rheological intensity distribution parameters of each region and the target intensity threshold, where the target intensity threshold is the nominal intensity value within the target intensity range.

6. The method for optimizing the process parameters of the retaining ring press column reduction based on strength parameters as described in claim 5, characterized in that, The method involves dynamically adjusting the next pass based on the deviation between the equivalent rheological intensity distribution parameters of each region and the target intensity threshold. Obtain the response delay time of the hydraulic system and the dynamic characteristic parameters of each servo proportional valve; Based on the response delay time and dynamic characteristic parameters, time-series compensation is performed on the equivalent rheological intensity distribution parameters of each region to generate correction commands corresponding to K hydraulic columns. The correction instructions are loaded into the servo proportional valve controllers corresponding to the K hydraulic columns.

7. The method for optimizing the process parameters of the retaining ring press column reduction based on strength parameters as described in claim 6, characterized in that, The method comprises constructing a joint parameter optimization loop using L suppression parameter sets corresponding to the first suppression parameter set, the second suppression parameter set, and the Lth suppression parameter set, and the method includes: The L-pass suppression process is used as an outer optimization loop, and inner-layer collaborative regulation is performed within each pass. Meanwhile, the convergence condition is that the equivalent rheological intensity parameters of each pass in the outer optimization loop all fall within the target intensity range.

8. The method for optimizing the process parameters of the retaining ring press column reduction based on strength parameters as described in claim 7, characterized in that, The inner-layer coordinated regulation includes: Based on the equivalent rheological intensity distribution parameters of the current pass, the power of the induction heating zone and the single-cylinder pressing speed, single-cylinder pressing force and single-cylinder stroke position of the K hydraulic columns are updated synchronously.

9. The method for optimizing process parameters of a retaining ring press with reduced column based on strength parameters as described in claim 8, characterized in that, The method further includes: After L passes of pressing are completed, the residual stress distribution of the key cross section of the retaining ring is collected by the ultrasonic residual stress detection unit. The residual stress distribution inversion intensity uniformity is fed back to the parameter joint optimization loop for initial value optimization.

10. A system for optimizing process parameters of a retaining ring press for reducing column size based on strength parameters, characterized in that, The system is used to implement the method for optimizing the process parameters of the retaining ring press based on strength parameters as described in any one of claims 1-9, wherein the system comprises: Sensor array setting module: After the surface pretreatment of the retaining ring blank is completed, it is placed in a multi-cylinder synchronous hydraulic press and a temperature sensor array and a pressure sensor array are set. The first pressing parameter set acquisition module determines the single-cylinder pressing speed, single-cylinder pressing force, and single-cylinder stroke position of the K hydraulic columns required for the first pass, and obtains the first pressing parameter set. The optimal parameter combination acquisition module: Based on the high-temperature constitutive model corresponding to the retaining ring billet, it collects and inputs temperature field data and pressure field data in real time. It constructs a parameter joint optimization loop through the L pressing parameter sets corresponding to the first pressing parameter set, the second pressing parameter set to the Lth pressing parameter set, and coordinates the control of induction heating index and infrared heating index to make the equivalent rheological strength parameters of each pass converge to the target strength range, thereby obtaining the optimal parameter combination.

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