A digital research and development method and system for full-process simulation and cross-scale design
By using a digital R&D system that integrates full-process simulation and cross-scale design, combined with big data and macroscopic mechanical models of materials, the problems of information lack and performance fluctuation in steel production have been solved, enabling efficient, personalized, and low-cost material R&D and production.
Patent Information
- Application Number
- CN202211377283.2
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- Filing Date
- 2022-11-04
- Publication Date
- 2026-01-02
- Estimated Expiration
- 2042-11-04
AI Technical Summary
The steel production process suffers from problems such as a lack of real-time information, significant performance fluctuations, high R&D costs, long cycles, and large differences in customer needs, resulting in low efficiency in material R&D.
A digital R&D system employing full-process simulation and cross-scale design, combined with big data, knowledge base, and macroscopic mechanical property models of materials, designs the microstructure and spatial distribution of materials, and optimizes the material production process through full-process simulation units.
This has resulted in improved stability of material product performance, met personalized needs, shortened the R&D cycle for new products, reduced costs, and increased production efficiency.
Smart Images
Figure CN115662549B_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The present application relates to the technical field of digital research and application of materials, in particular to a digital research and development method and system for full-process simulation and cross-scale design. BACKGROUND
[0002] As an important field of process manufacturing industry, the material industry is facing great demands for improving product quality and production efficiency, as well as many challenges such as saving resources, reducing costs, and being environmentally friendly. Data science and new generation information communication and artificial intelligence technology as the vanguard technology of the fourth industrial revolution have brought new ideas to the material industry and promoted the intelligent and digital transformation development of material technology.
[0003] Among them, the steel industry is a large and complex process industry, and each process of the full process is a "black box". From raw materials to products, a long process is needed, and in addition to limited apparent parameters, internal parameters of many links of steel production cannot be measured in real time, and real-time information is extremely lacking. At the same time, the production process of steel is long, has many influencing factors, strong coupling, and obvious performance fluctuations, and with the development of technology, customers in different fields have different demands for steel performance. In addition, the development of new materials usually uses "a large number of physical tests + trial and error method", which leads to high test cost, poor traceability, and a long research and development period.
[0004] Therefore, in view of the above situation, a new intelligent steel design method and simulation system must be found to develop products that meet customer needs at low cost and high efficiency, and ultimately to promote the progress of material science, technology and production. SUMMARY
[0005] The present application is proposed to solve the problems of performance fluctuation of existing material products, increasing demand for product individualization, and long research and development period of new varieties.
[0006] To solve the above technical problems, the present application provides the following technical scheme:
[0007] On the one hand, the present application provides a digital research and development system for full-process simulation and cross-scale design, which is applied to realize a digital research and development method for full-process simulation and cross-scale design. The system includes a cross-scale design unit and a full-process simulation unit.
[0008] Among them:
[0009] The cross-scale design unit is used to design the microstructure and spatial distribution of the material by using big data, knowledge base and material macro-mechanical performance model, and then complete the composition and process design of the material.
[0010] A whole-process simulation unit is configured to simulate a whole process of material production according to a composition of the material and a process design.
[0011] Optionally, the macro mechanical property model of the material includes a kinetic model, a thermodynamic model and a continuum model.
[0012] The cross-scale design unit is further configured to:
[0013] The composition of the material is designed based on the kinetic model and the thermodynamic model, so as to obtain a composition, a temperature and a microstructure parameter of a casting blank in a smelting process of the designed material.
[0014] The process of the material is designed based on the kinetic model and the continuum model, so as to obtain a deformation process and a force and energy parameter of the designed material.
[0015] The microstructure and the spatial distribution of the designed material are obtained according to the composition, the temperature and the microstructure parameter of the casting blank in the smelting process and the deformation process and the force and energy parameter.
[0016] Optionally, the whole-process simulation unit includes a material data management module, an equipment parameter management module, a simulation task management module, a simulation case management module and an external data interface management module.
[0017] In the material data management module:
[0018] The material data management module is configured to obtain parameters and models of the designed material.
[0019] The equipment parameter management module is configured to monitor and manage equipment parameters of each production process of the designed material.
[0020] The simulation task management module is configured to simulate a simulation process of each production process by using a simulation model in the simulation task management module, the parameters, the models and the equipment parameters of the designed material, so as to obtain a simulation result.
[0021] The simulation case management module is configured to post-process the simulation result and statistically analyze historical calculation data.
[0022] The external data interface management module is configured to obtain a detection result and a data collection result of an actual production process of the designed material, and dynamically adjust the simulation model.
[0023] Optionally, the material data management module is further configured to:
[0024] The material data management module is further configured to obtain the related parameters and the models of the designed material from a thermophysical property parameter library and a material constitutive model library.
[0025] Optionally, the simulation task management module is further configured to:
[0026] The simulation result is obtained by simulating each production process based on the parameters, model and equipment parameters of the designed material through the simulation model generator and the model solver.
[0027] Optionally, the simulation case management module is further used for:
[0028] According to the post-processing algorithm library and the historical case database, the simulation result is post-processed and the historical case data is counted.
[0029] Optionally, the external data interface management module is further used for:
[0030] According to the manufacturing execution system (MES), the detection result of the actual production process of the designed material is obtained.
[0031] According to the data acquisition system, the data acquisition result is obtained; wherein the data acquisition result includes the historical data of the actual production process.
[0032] The detection result and the data acquisition result are fed back to the whole-process simulation unit, and the simulation model is dynamically adjusted.
[0033] In another aspect, the present application provides a digital R&D method of whole-process simulation and cross-scale design, which is realized by a digital R&D system of whole-process simulation and cross-scale design, and the system includes a cross-scale design unit and a whole-process simulation unit; the method includes:
[0034] S1, based on the cross-scale design unit, the microstructure and spatial distribution of the material are designed by using big data, a knowledge base and a material macro-mechanical property model, and then the composition and process design of the material are completed.
[0035] S2, based on the whole-process simulation unit, the whole-process simulation of the material production process is completed according to the composition and process design of the material.
[0036] Optionally, the material macro-mechanical property model includes a dynamics model, a thermodynamics model and a continuum model.
[0037] The cross-scale design unit is further used for:
[0038] Based on the dynamics model and the thermodynamics model, the composition design of the material is performed to obtain the composition, temperature and casting blank microstructure parameters of the designed material in the smelting process.
[0039] Based on the dynamics model and the continuum model, the process design of the material is performed to obtain the deformation process and force-energy parameters of the designed material.
[0040] According to the composition, temperature and casting blank microstructure parameters in the smelting process and the deformation process and force-energy parameters, the microstructure and spatial distribution of the designed material are obtained.
[0041] Optionally, the whole-process simulation unit comprises a material data management module, an equipment parameter management module, a simulation task management module, a simulation case management module, and an external data interface management module.
[0042] Wherein:
[0043] The material data management module is configured to obtain parameters and models of the designed material.
[0044] The equipment parameter management module is configured to monitor and manage equipment parameters of each production process of the designed material.
[0045] The simulation task management module is configured to simulate each production process simulation based on simulation models in the simulation task management module, parameters, models, and equipment parameters of the designed material, to obtain simulation results.
[0046] The simulation case management module is configured to post-process the simulation results and statistically analyze historical case data.
[0047] The external data interface management module is configured to obtain detection results and data collection results of the actual production process of the designed material, and dynamically adjust the simulation models.
[0048] Optionally, the material data management module is further configured to:
[0049] Obtain relevant parameters and models of the designed material from a thermal physical property parameter library and a material constitutive model library.
[0050] Optionally, the simulation task management module is further configured to:
[0051] Simulate each production process simulation based on simulation models generated by a simulation model generator and a model solver, parameters, models, and equipment parameters of the designed material, to obtain simulation results.
[0052] Optionally, the simulation case management module is further configured to:
[0053] Post-process the simulation results and statistically analyze historical case data according to a post-processing algorithm library and a historical case database.
[0054] Optionally, the external data interface management module is further configured to:
[0055] Obtain detection results of the actual production process of the designed material from a manufacturing execution system (MES).
[0056] Obtain data collection results from a data collection system; wherein the data collection results include historical data of the actual production process.
[0057] The detection result and the data collection result are fed back to the whole-process simulation unit, and the simulation model is dynamically adjusted.
[0058] The technical scheme provided by the embodiment of the application has at least the following beneficial effects:
[0059] In the above scheme, the material is digitally developed by combining the cross-scale design method, and the designed product is evaluated and optimized by the whole-process simulation system, which helps to solve the problems of material product performance fluctuation, complex product individualization demand, and long new product development cycle. BRIEF DESCRIPTION OF DRAWINGS
[0060] In order to more clearly illustrate the technical scheme in the embodiment of the application, the drawings needed in the embodiment description will be briefly introduced as follows. Obviously, the drawings in the following description are only some embodiments of the application, and other drawings can be obtained by those skilled in the art without creative labor.
[0061] Figure 1 is a whole-process simulation and cross-scale design digital R&D system block diagram provided by the embodiment of the application;
[0062] Figure 2 is a schematic flow chart of the whole-process process simulation process provided by the embodiment of the application;
[0063] Figure 3 is a whole-process simulation and cross-scale design digital R&D method flowchart provided by the embodiment of the application. DETAILED DESCRIPTION
[0064] In order to make the technical problems, technical schemes and advantages of the application more clear, the following will be described in detail with reference to the drawings and specific embodiments.
[0065] As shown in Figure 1 The embodiment of the application provides a whole-process simulation and cross-scale design digital R&D system, which is applied to realize a whole-process simulation and cross-scale design digital R&D method, and the system comprises a cross-scale design unit and a whole-process simulation unit.
[0066] Among them:
[0067] The cross-scale design unit is used to design the microstructure and spatial distribution of the material by using big data, a knowledge base and a material macroscopic mechanical property model, and then complete the composition and process design of the material.
[0068] Optionally, the material macroscopic mechanical property model comprises a dynamics model, a thermodynamics model and a continuum model.
[0069] In one possible implementation, the big data and the knowledge base are used to establish the correlation between the performance of different materials and the microstructure. The material macro-mechanical performance model takes into account the fine-grain strengthening, solid solution strengthening, and precipitation strengthening.
[0070] The cross-scale design unit is further configured to:
[0071] The material composition design is performed based on the kinetic model and the thermodynamic model, to obtain the composition, temperature, and microstructure parameters of a casting blank in a smelting process of the designed material.
[0072] The material process design is performed based on the kinetic model and the continuum model, to obtain the deformation process and force-energy parameters of the designed material.
[0073] The microstructure and spatial distribution of the designed material are obtained according to the composition, temperature, and microstructure parameters of the casting blank in the smelting process, and the deformation process and force-energy parameters.
[0074] In one possible implementation, the cross-scale design is achieved in two aspects. One aspect is to achieve the cross-scale correlation between the material meso-level and the macro-level by establishing the correlation between the material microstructure and the macro-mechanical performance. The other aspect is to achieve the cross-scale correlation between the material micro-level, meso-level, and macro-level by using different scale models such as the first principle, kinetic model, thermodynamic model, and continuum model.
[0075] Further, the microstructure and spatial distribution need to be combined with the kinetic model to study the influence of the composition, temperature, and microstructure of the casting blank in the smelting process, and the deformation process and force-energy parameters.
[0076] Further, the kinetic model is used to study the evolution process of the internal microstructure of the material under external temperature, stress, and other conditions.
[0077] Further, the composition, temperature, and microstructure of the casting blank in the smelting process need to be designed by the thermodynamic model to obtain the related parameters. The thermodynamic model can determine the relationship between the steel composition and the phase composition by the first principle and thermodynamic calculation.
[0078] Further, the deformation process and force-energy parameters need to be designed by the continuum model to obtain the related parameters. The continuum model is based on the continuum theory, and constructs a numerical calculation model of the flow field, temperature field, and stress-strain field according to the actual production process parameters.
[0079] The whole-process simulation unit is configured to perform the simulation of the whole process of the material production procedure according to the composition and process design of the material.
[0080] Optionally, the whole-process simulation unit comprises a material data management module, a device parameter management module, a simulation task management module, a simulation case management module, and an external data interface management module.
[0081] In an embodiment, the whole-process simulation unit is an integrated system based on a digital process simulation platform, comprising a material data management module, a device parameter management module, a simulation task management module, a simulation case management module, and an external data interface management module.
[0082] In the embodiment, the whole-process simulation unit is an integrated system based on a digital process simulation platform, comprising a material data management module, a device parameter management module, a simulation task management module, a simulation case management module, and an external data interface management module.
[0083] The material data management module is configured to obtain parameters and models of the designed material.
[0084] Optionally, the material data management module is further configured to:
[0085] The material data management module is configured to obtain parameters and models of the designed material from a thermal physical property parameter library and a material constitutive model library.
[0086] The device parameter management module is configured to monitor and manage device parameters of each production process of the designed material.
[0087] In an embodiment, the device parameter management module is configured to monitor and manage device parameters of the whole-process production of the material.
[0088] In the embodiment, the whole-process simulation unit is an integrated system based on a digital process simulation platform, comprising a material data management module, a device parameter management module, a simulation task management module, a simulation case management module, and an external data interface management module.
[0089] Specifically, each production process can comprise process parameters such as steelmaking, continuous casting, heating, rolling, and cooling.
[0090] The simulation task management module is configured to simulate each production process by using a simulation model in the simulation task management module, parameters and models of the designed material, and device parameters, to obtain simulation results.
[0091] Optionally, the simulation task management module is further configured to:
[0092] The simulation task management module is configured to simulate each production process by using a simulation model in the simulation task management module, parameters and models of the designed material, and device parameters, to obtain simulation results.
[0093] In an embodiment, the model solver can comprise a Simusage process simulation development component library, ANSYS engineering design simulation software, Therm-Calc thermodynamic calculation software, MICRESS microstructure evolution simulation software, and Matlab.
[0094] For example, as shown in Figure 2 The steelmaking process simulation completes the establishment of the converter simulation simulation molten steel composition model, and based on the metallurgical thermodynamics, kinetic theory, according to the reaction principle of gas-liquid reaction zone and slag-steel reaction zone, the real-time simulation calculation of molten steel composition.
[0095] The steelmaking process simulation completes the establishment of the converter simulation simulation molten steel temperature and slag composition model, and according to the dynamic heat balance and material balance of the converter reaction, the real-time simulation of the change of slag composition and molten steel temperature.
[0096] The continuous casting process simulation will complete real-time simulation according to the slab temperature field model, slab macroscopic solidification structure model and macroscopic segregation model.
[0097] The heating process simulation includes slab temperature simulation module, furnace atmosphere simulation module and decarburization simulation module.
[0098] The rolling process simulation includes rolling temperature field simulation module, rolling process deformation simulation module and recrystallization / grain growth simulation.
[0099] The cooling process simulation includes temperature field simulation module, cooling process organization structure evolution module and macroscopic mechanical property prediction module. The cooling process simulation model considers the different external cooling conditions of the lap joint and non-lap joint (different wind speeds at different positions of the wheel track), and the different stacking densities at different positions of the coil.
[0100] The simulation case management module is used for post-processing of the simulation results and historical example data statistics.
[0101] Optionally, the simulation case management module is further used for:
[0102] According to the post-processing algorithm library and the historical example database, the simulation results are post-processed and the historical example data is statistically analyzed.
[0103] The external data interface management module is used to obtain the detection results and data collection results of the actual production process of the designed material, and dynamically adjust the simulation model.
[0104] Optionally, the external data interface management module is further used for:
[0105] According to the manufacturing execution system MES, the detection results of the actual production process of the designed material are obtained.
[0106] In a feasible implementation manner, the MES (Manufacturing Execution System) is used to monitor and perfect the production plan and process specification.
[0107] According to the data acquisition system, the data acquisition results are obtained.
[0108] The data collection result includes historical data of the actual production process.
[0109] In an implementation, the data collection system mainly collects historical data of the actual production.
[0110] The detection result and the data collection result are fed back to the whole-process simulation unit, and the simulation model is dynamically adjusted.
[0111] In the embodiment of the application, the method of cross-scale design is combined to digitally develop the material, and the designed product is evaluated and optimized through the whole-process simulation system, which helps to solve the problems of material product performance fluctuation, complex product individualization demand, long new product development cycle, etc.
[0112] As shown in Figure 3 The embodiment of the application provides a whole-process simulation and cross-scale design digital development method, which can be realized by a whole-process simulation and cross-scale design digital development system. Figure 3 As shown in the flow chart of the whole-process simulation and cross-scale design digital development method, the processing flow of the method can include the following steps:
[0113] S1, based on the cross-scale design unit, the microstructure and spatial distribution of the material are designed by using big data, a knowledge base and a material macro-mechanical property model, and then the composition and process design of the material are completed.
[0114] S2, based on the whole-process simulation unit, the whole-process simulation of the material production process is completed according to the composition and process design of the material.
[0115] Optionally, the material macro-mechanical property model includes a dynamics model, a thermodynamics model and a continuum model.
[0116] The cross-scale design unit is further used for:
[0117] Based on the dynamics model and the thermodynamics model, the composition of the material is designed to obtain the composition, temperature and casting blank microstructure parameters of the designed material in the smelting process.
[0118] Based on the dynamics model and the continuum model, the process of the material is designed to obtain the deformation process and force-energy parameters of the designed material.
[0119] According to the composition, temperature and casting blank microstructure parameters in the smelting process and the deformation process and force-energy parameters, the microstructure and spatial distribution of the designed material are obtained.
[0120] Optionally, the whole-process simulation unit includes a material data management module, an equipment parameter management module, a simulation task management module, a simulation case management module and an external data interface management module.
[0121] wherein:
[0122] a material data management module configured to obtain parameters and models of the designed material.
[0123] a device parameter management module configured to monitor and manage device parameters of each production process of the designed material.
[0124] a simulation task management module configured to simulate each production process by using a simulation model in the simulation task management module, the parameters and models of the designed material, and the device parameters, to obtain a simulation result.
[0125] a simulation case management module configured to post-process the simulation result and to statistically analyze historical calculation examples.
[0126] an external data interface management module configured to obtain detection results and data collection results of an actual production process of the designed material, and to dynamically adjust the simulation model.
[0127] Optionally, the material data management module is further configured to:
[0128] obtain the parameters and models of the designed material from a thermal physical parameter library and a material constitutive model library.
[0129] Optionally, the simulation task management module is further configured to:
[0130] simulate each production process by using a simulation model generator and a model solver based on the parameters and models of the designed material and the device parameters, to obtain the simulation result.
[0131] Optionally, the simulation case management module is further configured to:
[0132] post-process the simulation result and statistically analyze historical calculation examples according to a post-processing algorithm library and a historical calculation example database.
[0133] Optionally, the external data interface management module is further configured to:
[0134] obtain the detection results of the actual production process of the designed material from a manufacturing execution system (MES).
[0135] obtain the data collection results from a data collection system; wherein the data collection results include historical data of the actual production process.
[0136] feed back the detection results and the data collection results to the full-process simulation unit, and dynamically adjust the simulation model.
[0137] In the embodiment of the present application, the material is digitally researched and developed in combination with the method of cross-scale design, and the designed product is evaluated and optimized through a full-process simulation system, which helps to solve the problems of material product performance fluctuation, complex product individualization demand, long new variety research and development cycle and the like.
[0138] Those skilled in the art can understand that all or part of the steps of the above-mentioned embodiments can be completed by hardware, or by program instructing relevant hardware to complete, and the program can be stored in a computer readable storage medium, which can be a read-only memory, a magnetic disk or an optical disk.
[0139] The above only describes the preferred embodiments of the present application and is not intended to limit the present application. Any modification, equivalent replacement, improvement and the like made within the spirit and principle of the present application shall be included in the protection scope of the present application.
Claims
1. A digital R&D system for full flow simulation and cross-scale design, characterized in that, The system comprises a cross-scale design unit and a whole-process simulation unit; wherein: The cross-scale design unit is configured to design microstructure and spatial distribution of a material by using big data, a knowledge base and a material macro-mechanical performance model, and to complete component and process design of the material; The whole-process simulation unit is configured to complete simulation of the whole process of material production according to the component and process design of the material; The material macro-mechanical performance model comprises a kinetic model, a thermodynamic model and a continuum model; The cross-scale design unit is further configured to: perform material component design based on the kinetic model and the thermodynamic model to obtain smelting process component, temperature and casting blank microstructure parameters of the designed material; perform material process design based on the kinetic model and the continuum model to obtain deformation process and force and energy parameters of the designed material; obtain microstructure and spatial distribution of the designed material according to the smelting process component, temperature and casting blank microstructure parameters and the deformation process and force and energy parameters; The whole-process simulation unit comprises a material data management module, an equipment parameter management module, a simulation task management module, a simulation case management module and an external data interface management module; The material data management module is configured to obtain parameters and models of the designed material; The equipment parameter management module is configured to monitor and manage equipment parameters of each production process of the designed material; The simulation task management module is configured to simulate each production process simulation process by using a simulation model in the simulation task management module, parameters, models and equipment parameters of the designed material to obtain simulation results; The simulation case management module is configured to post-process the simulation results and statistically analyze historical example data; The external data interface management module is configured to obtain detection results and data collection results of an actual production process of the designed material, and dynamically adjust the simulation model.
2. The system of claim 1, wherein, The material data management module is further configured to: obtain relevant parameters and models of the designed material from a thermal physical property parameter library and a material constitutive model library.
3. The system of claim 1, wherein, The simulation task management module is further configured to: simulate each production process simulation process by using a simulation model generator and a model solver based on parameters, models and equipment parameters of the designed material to obtain simulation results.
4. The system of claim 1, wherein, The simulation case management module is further configured to: post-process the simulation results and statistically analyze historical example data according to a post-processing algorithm library and a historical example database.
5. The system of claim 1, wherein, The external data interface management module is further configured to: obtain detection results of an actual production process of the designed material from a manufacturing execution system (MES); obtain data collection results from a data collection system; wherein the data collection results comprise historical data of the actual production process; feed back the detection results and the data collection results to the whole-process simulation unit, and dynamically adjust the simulation model.
6. A digital R&D method for full flow simulation and cross-scale design, characterized in that, The method is realized by a digital research and development system of whole-process simulation and cross-scale design, the system comprises a cross-scale design unit and a whole-process simulation unit; and the method comprises: S1, based on the cross-scale design unit, using big data, knowledge base and material macro mechanical property model, design the microstructure and spatial distribution of the material, and then complete the composition and process design of the material; S2, based on the whole process simulation unit, according to the composition and process design of the material, complete the simulation of the whole process of material production procedure; The material macro mechanical property model includes dynamics model, thermodynamics model and continuum model; The cross-scale design unit is further used for: Based on the dynamics model and thermodynamics model, the composition of the material is designed, and the composition, temperature and microstructure parameters of the designed material in the smelting process are obtained; Based on the dynamics model and continuum model, the material process design is carried out, and the deformation process and force energy parameters of the designed material are obtained; According to the composition, temperature and microstructure parameters of the smelting process and the deformation process and force energy parameters, the microstructure and spatial distribution of the designed material are obtained; The whole process simulation unit includes material data management module, equipment parameter management module, simulation task management module, simulation case management module and external data interface management module; Wherein: the material data management module is used for obtaining the parameters and model of the designed material; The equipment parameter management module is used for monitoring and managing the equipment parameters of each production process of the designed material; The simulation task management module is used for simulating the simulation process of each production process by the simulation model in the simulation task management module, the parameters, model and equipment parameters of the designed material, and obtaining the simulation result; The simulation case management module is used for post-processing and historical example data statistics of the simulation result; The external data interface management module is used for obtaining the detection result and data acquisition result of the actual production process of the designed material, and dynamically adjusting the simulation model.
Citation Information
Patent Citations
Melt-cast explosive digital development and manufacturing method
CN107512996A
Digital test system and method for dimension variety and distortion of textile
WO2010015193A1