Shear deformation and plate shape control of hot-rolled aluminium alloy thick plate prepared by asymmetric rolling process

Asymmetric rolling （ASR）, as one of severe plastic deformation （SPD） methods to make ultra-fine materials with enhanced performance is mainly used to prepare foil and thin strip. The asymmetrical rolling was achieved by adjusting the diameters of the upper roll and the bottom roll and was used to prepare hot-rolled thick plate of 5182 aluminium alloy. The shear deformation and plate shape control were experimentally studied. The experimental results show that asymmetrical rolling has a significant effect on metal deformation stream and can somehow refine microstructure and improve the uniformity of microstructure and properties. The asymmetrical rolling process can also reduce the rolling force. However, bending of rolling plate often happens during asymmetrical rolling process. The factors affecting the bending were discussed.

Theoretical analysis of minimum metal foil thickness achievable by asymmetric rolling with fixed identical roll diameters

A novel approach is proposed for computing the minimum thickness of a metal foil that can be achieved by asymmetric rolling using rolls with identical diameter. This approach is based on simultaneously solving Tselikov equation for the rolling pressure and the modified Hitchcock equation for the roller flattening. To minimize the effect of the elastic deformation on the equal flow per second during the ultrathin foil rolling process, the law of conservation of mass was employed to compute the proportions of the forward slip, backward slip, and the cross shear zones in the contact arc, and then a formula was derived for computing the minimum thickness for asymmetric rolling. Experiment was conducted to find the foil minimum thickness for 304 steel by asymmetric rolling under the asymmetry ratios of 1.05, 1.15 and 1.30. The experimental results are in good agreement with the calculated ones. It was validated that the proposed formula can be used to calculate the foil minimum thickness under the asymmetric rolling condition.

Effect of asymmetric rolling process on the microstructure,mechanical properties and texture of AZ31 magnesium alloys sheets produced by twin roll casting technique

Symmetric rolling(SR)and asymmetric rolling(ASR)processes were carried out on 6 mm thick AZ31 magnesium alloy sheets that were produced by twin roll casting(TRC)technique.Before rolling processes,sheets were heat treated in order to obtain a homogenized microstructure.In this study,for the ASR process the rolling speed ratio between upper roller and lower was selected as 1.25.Both SR and ASR processes were utilized with 40%reduction per passes using 2 pass schedule for a total reduction ratio of 0.67.Symmetric and asymmetric rolled sheets were characterized using optical microscopy(OM),scanning electron microscopy(SEM)and transmission electron microscopy(TEM)techniques.Texture measurements were performed by using X-ray diffraction(XRD)technique and mechanical properties were investigated by tensile tests and also hardness measurements.

Influence of rolling route on microstructure and mechanical properties of AZ31 magnesium alloy during asymmetric reduction rolling

Four different routes of asymmetric reduction rolling were conducted on AZ31 magnesium alloy to investigate their effect on the microstructure evolution and mechanical properties. Route A is the forward rolling; while during routes B and C the sheets are rotated 180o in rolling direction and normal direction, respectively; route D is the unidirectional rolling. The strain states of rolled sheets were analyzed by the finite element method, while the microstructure and texture were observed using optical microscopy, X-ray diffraction and electron back-scattered diffraction techniques, and the mechanical properties were measured by tensile test. The results show that route D produced the largest effective strain. Compared with other samples, sample D exhibited a homogeneous microstructure with fine grains as well as a weak and tilted texture, in corresponding, it performed excellent tensile properties, which suggested that route D was an effective way to enhance the strength and plasticity of AZ31 sheet.

Effect of asymmetric rolling under high friction coefficient on recrystallization texture and plastic anisotropy of AA1050 alloy

In asymmetric rolling(ASR) the circumferential velocities of the working rolls are different. This yields a complex deformation mode with shear, compression and rigid body rotation components. The main microstructural modification is on crystallographic texture, and, for aluminium alloys, this may improve the deformability after recrystallization. This work correlated the process variables, thickness reduction per pass(TRP) and velocity ratio between the upper and bottom rolls, with the texture development and the plastic properties after annealing. Finite element(FE) simulations were performed to quantify the influence of the strain components. Experimental data on texture, and plastic anisotropy were analyzed. In the sheet centre a crystallographic rotation of the compression components about the TD(transverse direction) axis was obtained, which yielded the development of {111}//ND(normal direction) texture components. On the surfaces the local variation of the velocity gradients caused an extra rotation component about ND. This yielded the increment of rotated cube components. After annealing the main texture components at the sheet centre were maintained and the texture intensity decreased. The planar anisotropy(△r) was reduced but the normal anisotropy and deep drawability obtained by the Erichsen test were similar for all conditions. The most favourable reduction of △r was obtained at a velocity ratio of 1.5 and TRP of 10%.

Evolution of microstructure and mechanical properties of ZK60 magnesium alloy processed by asymmetric lowered-temperature rolling

Asymmetric lowered-temperature rolling was applied to the fabrication of fine-grained ZK60 magnesium alloy sheet with weak basal texture along the rolling direction(RD).The results showed that multi-pass lowered-temperature rolling could significantly improve the microstructure homogeneity and refine the grain size.Meanwhile,a fiber texture along the transverse direction(TD)gradually developed during rolling process.Importantly,the shear deformation along the RD made the c-axis of basal plane rotate to the RD,weakening the basal texture along this direction.Influenced by such microstructure variation,the yield strength along the TD continuously increased due to the successive grain refinement and the increased activation of prismatic slips,whereas the uniform elongation decreased owing to the decline of strain hardening ability.In contrast,the continuous weakening of basal texture along the RD increased the activation of soft basal slips,greatly offsetting the strengthening effect contributed by grain refinement and thereby causing the slight decrease of yield strength.

Finite element analysis and experiment on multi-wedge cross wedge rolling for asymmetric stepped shaft of C45

A rigid-plastic finite element method(FEM) simulation model for a multi-wedge cross wedge rolling(MCWR) was developed to analyze an asymmetric stepped shaft. To evaluate the MCWR process and better understand its deformation characteristics, the material flowing mechanisms, temperature distributions, strain and rolling force were analyzed. The correctness of the finite element simulation is experimentally verified. Numerical simulations and experiments led to the following conclusions: when α=36° and β=7.5°, the quality of the work piece can be significantly improved. Finally, the development of the asymmetric stepped shaft is applied to industrial production.

Ultrafine microstructure and texture evolution of aluminum foil by asymmetric rolling

AA1060 aluminum foil was rolled from 4 mm to 20 μm by asymmetric rolling without intermediate annealing. The microstructures and textures were investigated. The original coarse grains with an average grain size of 60 μm were refined to fine equiaxed grains with an average grain size of about 500 nm with mainly large grain boundaries. During the rolling, the intensities of copper texture C-{112}<111> and brass texture B-{011}<211> gradually increased, and most crystallites aggregated along the β and τ orientation lines. The orientation intensity reached the maximum value 26 when the foil was rolled to 500 μm, but significantly decreased to 16 when the thickness became 20 μm, and the texture mainly consisted of a rotation cubic texture RC-{100}<011>. With the combined forces including drawing, compressing and shearing, severe plastic deformation was obtained during the asymmetric rolling, promoting dynamic recrystallization at room temperature. Because of a combined force in the deformation zone and shear force along the normal direction, dynamic recrystallization occurs during the asymmetric rolling; therefore, the average grain size is significantly refined. The texture intensity of ultrathin strip first increases, i.e., work hardening, and then decreases mainly because of dynamic recrystallization.

Effects of interrupted ageing and asymmetric rolling on microstructures, mechanical properties, and intergranular corrosion behavior of Al-Mg-Si-Zn alloy

Effects of interrupted ageing(T6I6) and asymmetric rolling on microstructures, mechanical properties, and intergranular corrosion(IGC) behaviors of Al-Mg-Si-Zn alloy were investigated. Results showed that the T6 alloy has the lowest strength and the worst IGC resistance, while the T6I6 alloy has higher strength and better IGC resistance.What’ s more, the alloy treated by pre-rolling deformation has higher strength and better IGC resistance;and the alloy treated by the pre-asymmetry rolling achieves the highest strength, the best IGC resistance and lower elongation. The mechanical properties depend on microstructures such as the grain size, texture, dislocation density and precipitation, the grain boundary misorientation and grain boundary microstructure are responsible for the IGC resistance.

Shear deformation and grain refinement in pure Al by asymmetric rolling

Asymmetric rolling(ASR), as one of severe plastic deformation(SPD) methods, was widely used to make ultra-fined materials with enhanced performance. Internal marks were used to show the shear deformation during asymmetric rolling with pure aluminium as a model material. Effects of reduction ratio and mismatch ratio on the shear deformation were studied. With the observed shear deformation results, equivalent strain was calculated. For lager shear deformation, rolling equipment was modified to increase friction between specimen and the rollers. Consequently, extremely fine grains with size of 500 nm are obtained in pure aluminium. With improved asymmetric rolling, the ability of grain refinement of ASR is greatly improved.

Effects of asymmetric rolling process on ridging resistance of ultra-purified 17%Cr ferritic stainless steel

In ferritic stainless steels, a significant non-uniform recrystallization orientation and a substantial texture gradient usually occur, which can degrade the ridging resistance of the final sheets. To improve the homogeneity of the recrystallization orientation and reduce the texture gradient in ultra-purified 17%Cr ferritic stainless steel, in this work, we performed conventional and asymmetric rolling processes and conducted macro and micro-texture analyses to investigate texture evolution under different cold-rolling conditions. In the conventional rolling specimens, we observed that the deformation was not uniform in the thickness direction, whereas there was homogeneous shear deformation in the asymmetric rolling specimens as well as the formation of uniform recrystallized grains and random orientation grains in the final annealing sheets. As such, the ridging resistance of the final sheets was significantly improved by employing the asymmetric rolling process. This result indicates with certainty that the texture gradient and orientation inhomogeneity can be attributed to non-uniform deformation, whereas the uniform orientation gradient in the thickness direction is explained by the increased number of shear bands obtained in the asymmetric rolling process.

Recrystallized microstructural evolution of UFG copper prepared by asymmetrical accumulative rolling-bonding process

Copper sheet with grain size of 30-60μm was processed by plastic deformation of asymmetrical accumulative rolling-bonding(AARB)with the strain of 3.2.The effects of annealing temperature and time on microstructural evolution were studied by means of electron backscattered diffraction(EBSD).EBSD grain mapping,recrystallization pole figure and grain boundary misorientation angle distribution graph were constructed,and the characteristics were assessed by microstructure,grain size,grain boundary misorientation and texture.The results show that ultra fine grains(UFG)are obtained after annealing at 250℃ for 30?40 min.When the annealing is controlled at 250℃for 40 min,the recrystallization is finished,a large number of small grains appear and most grain boundaries consist of low-angle boundaries.The character of texture is rolling texture after the recrystallization treatment,but the strength of the texture is faint.While second recrystallization happens,{110}<1ī2>+{112}<11ī> texture component disappears and turns into{122}<212>cube twin texture component.

Effect of asymmetric rolling on mechanical characteristics,texture and misorientations in ferritic steel

The mechanical and microstructural properties as well as crystallographic textures of asymmetrically rolled low carbon steel were studied.The modelling of plastic deformation was carried out in two scales:in the macro-scale,using the finite elements method,and in the crystallographic scale,using the polycrystalline deformation model.The internal stress distribution in the rolling gap was calculated using the finite elements method and these stresses were then applied to the polycrystalline elasto-plastic deformation model.Selected mechanical properties,namely residual stress distribution,deformation work,applied force and torques,and bend amplitude,were calculated.The diffraction measurements,X-ray and electron backscatter diffraction,enabled the examination of texture heterogeneity and selected microstructure characteristics.The predicted textures agree well with those determined experimentally.The plastic anisotropy of cold rolled ferritic steel samples,connected with texture,was expressed by Lankford coefficient.

Influence of Asymmetric Monotonic Hot Rolling on Microstructures and Mechanical Property of Microalloyed Steel

For refining grain and obtaining excellent properties, the experiments of asymmetric and symmetric monotonic hot rolling were carried out to investigate the role of shear strain on the microstructures and mechanical properties of V-microalloyed steel. The study demonstrates that the gradient ferrite distribution and dispersive pearlite through the sheet thickness are observed in asymmetric rolled specimen, and the homogeneous microstructure with ferrite and large pearlite is found in symmetric rolled specimen. The average grain size in asymmetric rolled specimen is smaller than the one in symmetric rolled specimen. The styles of precipitate morphology in asymmetric rolled specimen are random precipitate and obvious interphase precipitate, while the ones in symmetric rolled specimen are random precipitate and unobvious interphase precipitate. The additional shear strain results in the microstructure difference between asymmetric rolled specimen and symmetric rolled specimen. The impact energy of asymmetric rolled specimen, 58 J, is more than the one of symmetric rolled specimen, 48 J. Both deflection-energy curve and fracture morphology show that the fracture style of asymmetric rolled specimen is ductile, and the ones of symmetric rolled specimen are brittle and ductile.

Research on Single-Side Long Edge of Hot Rolled Strip Caused by Asymmetrical Stiffness of Mill Stand

To analyze and solve the problem of single-side long edge of hot rolled strip in certain domestic factory, the asymmetrical deformation of rolls and strip in asymmetrical stiffness mill stand based on slit beam model, the strip profile and rolling force distribution at the exit of asymmetric stiffness stand mill were calculated using influence function method. Considering the character of in-site equipment and technology, a scheme of adjusting load distribution in finishing mill was made and the experiment was applied. Comparison of strip profile between new load distribution and the old one shows that the method can solve single-side long edge problem well.

A Modified Logvinovich Model For Hydrodynamic Loads on an Asymmetric Wedge Entering Water with a Roll Motion

The water entry problem of an asymmetric wedge with roll motion was analyzed by the method of a modified Logvinovich model (MLM). The MLM is a kind of analytical model based on the Wagner method, which linearizes the free surface condition and body boundary condition. The difference is that the MLM applies a nonlinear Bernoulli equation to obtain pressure distribution, which has been proven to be helpful to enhance the accuracy of hydrodynamic loads. The Wagner condition in this paper was generalized to solve the problem of the water entry of a wedge body with rotational velocity. The comparison of wet width between the MLM and a fully nonlinear numerical approach was given, and they agree well with each other. The effect of angular velocity on the hydrodynamic loads of a wedge body was investigated.

Analysis of bending on the front end of sheet during hot rolling

The analysis of bending in finishing rolling was performed. An asymmetrical rolling force model was established, and the upper and lower neutral points were determined. Thc bending which resulted from the asymmetrical rolling force at the roll gap was studied and related flexibility equations were proposed according to elastic mechanics. Moreover, material mechanics was used to analyze the effects of temperature difference and self-weight on the bending out of the roll gap, and the flexibility equations were constructed. The main factors on bending were summed up, and the bending rule in the rolling could be obtained. In addition practical calculation was made with the production data of ribbon steel from Laiwu Iron ＆ Steel Group Co. Ltd.

Evolution of {001}<110> orientation and related lattice rotation of Al alloy 6111 during rolling

The texture evolution and lattice rotation in Al alloy 6111 with an initial {001} <110> component during symmetrical and asymmetrical rolling were investigated by means of orientation distribution function(ODF). The results show that the as-rolled initial {001}<110 > entation evolves into not only the copper orientation but also all the other orientations along the β fiber, including the brass orientation, by lattice rotation around special directions. Compared with the symmetrical rolling, the {001}<110 > component in the surface layer on the slower roller side evolves more quickly into the orientations along the β fiber during asymmetrical rolling, while that in the surface layer on the faster roller side evolves more slowly.

Approximation Method for Flare Slamming Analysis of Large Container Ships in Parametric Rolling Conditions

Since the research of flare slamming prediction is seldom when parametric rolling happens, we present an efficient approximation method for flare slamming analysis of large container ships in parametric rolling conditions. We adopt a 6-DOF weakly nonlinear time domain model to predict the ship motions of parametric rolling conditions. Unlike previous flare slamming analysis, our proposed method takes roll motion into account to calculate the impact angle and relative vertical velocity between ship sections on the bow flare and wave surface. We use the Wagner model to analyze the slamming impact forces and the slamming occurrence probability. Through numerical simulations, we investigate the maximum flare slamming pressures of a container ship for different speeds and wave conditions. To further clarify the mechanism of flare slamming phenomena in parametric rolling conditions, we also conduct real-time simulations to determine the relationship between slamming pressure and 3-DOF motions, namely roll, pitch, and heave.

改进卷积胶囊网络的滚动轴承故障诊断方法

目前许多基于卷积网络的滚动轴承故障诊断方法受噪声信号以及负荷变化的影响,存在诊断效果不佳、泛化能力差的问题。针对此问题提出一种改进卷积胶囊网络的滚动轴承变工况故障诊断方法。该方法设计了多尺度非对称卷积模块,其中采用不同尺度的非对称卷积层对输入数据进行特征提取,在实现最大化提取数据中的特征信息的同时,还能够有效减少参数量;在该模块中引入通道注意力机制,能更好地提取有用的通道特征,提高该方法特征提取的能力;通过将网络中的全连接层改进为胶囊全连接层,使得胶囊在输出向量特征信息时,避免了特征信息在空间中的丢失。使用凯斯西储大学轴承数据集和东南大学变速箱数据集来验证所提方法的诊断性能,并与其他深度学习方法进行了比较。实验结果表明,与其他深度学习方法相比,具有较好的泛化性,效果更佳。