Optimum rolling speed and relevant temperature-and reduction-dependent interfacial friction behavior during the break-down rolling of AZ31B alloy

The present study aimed to determine the optimum rolling speed for break-down rolling of as-cast AZ31 B alloy and investigated the friction behavior associated with temperature-and reduction-sensitivity at the roll/plate contact interface. Tensile testing, formability evaluation and microstructural studies relevant to different rolling speeds were performed and finally the optimum operating rolling speed（50.0 ± 0.8 m/min） was obtained. Further, the effects of rolling reduction and initial temperature were assessed on the temperature variation, lateral spread and interfacial friction behavior at optimum rolling speed. The results showed that lower rolling speed（18.0 ± 0.8 m/min） resulted in an incompletely recrystallized structure where twins occupied relatively high volume fraction. Twinning dominated the deformation at rolling speed exceeding the optimum, resulting in the local recrystallization with shear bands and coarse grains. Rolling at 50.0 ± 0.8 m/min could get the best overall tensile properties and rolling formability due to the relatively high recrystallization degree and microstructure uniformity. An inverse method has been developed to determine the interfacial friction coefficient during interaction of AZ31 B alloy with roll surfaces. When rolling at the optimum speed, the interfacial friction coefficient ranged from 0.16 to 0.58, which was strongly positively correlated with the reduction but slightly positively correlated with the initial temperature. Depended on the rolling characteristics, external friction effect coefficient ranged from 1.25 to 2.35 and it exhibited positive correlation with both the initial rolling temperature and rolling reduction.

Influence of roll speed difference on microstructure, texture and mechanical properties of 7075 aluminum plates produced via combined continuous casting and rolling process

The influences of the dissimilarity in the roll speeds on the microstructure, texture and mechanical properties of 7075 aluminum plates produced via combined continuous casting and rolling(CCCR) process were investigated. Several experiments were conducted with three different upper/lower roll rotational speed ratios(ω/ω0, ω is the upper roll rotational speed and ω0 is the lower roll rotational speed), namely 1:1, 1:1.2 and 1:1.4. It was found that the greatest dissimilarity in the roll speed(ω/ω0=1:1.4) improved the yield strength and ultimate tensile strength of 7075 Al plate in the rolling direction by 41.5% and 21.9%, respectively. Moreover, at a roll speed ratio of ω/ω0=1:1.4, the average grain size was decreased by 36% whereas the mean hardness of the transverse cross-section of the finally rolled plate was increased by about 9.2%. Texture studies also revealed that the more the difference in the roll speeds was, the greater the isotropy and the hardness of the final product were. Nevertheless, conducting CCCR operation with different roll speeds resulted in about 6% reduction in the elongation of the deformed plate.

Effect of driver roll rotational speed on hot ring rolling of AZ31 magnesium alloy

Based on the ABAQUS/Explicit code,A 3D elastic-plastic and coupled thermo-mechanical FE model of radial ring rolling of AZ31 Magnesium alloy has been proposed to analyze the influence of rotational speed of driver roll to study the inhomogeneity distribution of strain and temperature,fishtail coefficient,rolling force parameters.The results show that:(1)when the rotational speed of driver roll n increases,the strain distribution of the rolled ring becomes less homogeneous,and the temperature distribution more homogeneous yet,and leading to an optimal n value;(2)the fishtail coefficient firstly decreases,then increases with the increase of n;(3)the rolling force,contact area and rolling moment gradually descend with the increase of n.

Computer simulation of core filling process of cast high speed steel roll

Core filling process of cast high speed steel roll was simulated.Ductile iron was used as core material.The influences of filling parameters,such as core filling time and core filling temperature,on the filling process were investigated.Based on the simulated results,optimal core filling parameters were determined.The predicted temperature fields show that the temperature at the roll shoulder is the lowest during the core filling process and usually causes binding defects there.Method for solving this problem was presented.

Experimental research on electromagnetic continuous casting high-speed steel composite roll

A high speed steel composite roll billet was fabricated, which is regular in shape, smooth in surface, slight in trace, compact in internal structure, free of slag inclusion, shrinkage cavity, cracks and other flaws, and good in macro quality of junction surface using a vertical continuous casting machine. The interface zone microstructure of bimetallic in billet of high speed steel composite roll was analyzed by metallurgical microscope(OM), X-ray diffractmeter(XRD), scanning electron microscopy(SEM) and energy-dispersive X-ray analysis(EDS). The results indicate that the microstructure of roll billet is composed of chilled solidified layer, dendrite zone, interfacial zone of bimetal and core material zone. The microstructure of outer shell material is composed of martensite + bainite + residual austenite + some small labyrinth-shape, small-short lath-shape, or dollop-shape eutectic carbides. The microstructure of core material is slice-shape pearlite and a little ferrite along boundary of cells. The interface region microstructure of bimetallic composite roll consists of diffusion region, chilled solidified layer and columnar grain region.

Effect of quenching temperature on structure and properties of centrifugal casting high speed steel roll

The critical points and time-temperature-transformation(TTT)curves of the isothermal transformation diagrams for a high-speed steel casting on a horizontal centrifugal casting machine had been determined experimentally in the study.The effects of quenching temperature on the microstructures and properties of centrifugal casting high speed steel(HSS)roll has been investigated using scanning electron microscopy(SEM), light optical microscopy(LOM)and X-ray diffraction(XRD)as well as using tensile,impact,and hardness tests. The results show that the HSS roll has excellent hardenability and its matrix structure can be transformed into the martensite after being quenched in the sodium silicate solution.The retained austenite in the quenching structure increases and the hardness decreases when the quenching temperature exceeds 1,040℃.The tensile strength and impact toughness of HSS roll increase once the quenching temperature is raised from 980℃to 1,040℃. However,the tensile strength and impact toughness have no significant change when the quenching temperature exceeds 1,040℃.The HSS roll quenched at 1,040℃exhibits excellent comprehensive mechanical properties.

Determination of the Influence of the Speed of the Saw Cylinder of the Saw Gin on the Density, Speed and Composition of the Seed Roll

The article consists of studying the influence of the speed of the saw cylinder on the quality of the fiber and the productivity of the machine, as well as on the change in the density and composition of the seed roll.

Dynamics-based optimization of rolling schedule aiming at dual goals of chatter suppression and speed increase for a 5-stand cold tandem rolling mill

In the process of cold tandem rolling,chatter instability leads to serious impacts on enhancing rolling speed,improving product quality,reducing production cost and realizing intellectualization.Chatter occurs with the rolling speed up to a certain threshold value,but the critical speed is determined by both product specifications and rolling schedules.A 5-stand cold tandem rolling mill whose first three stands and subsequent two stands,respectively,have four and six rolls was investigated by formulating its dynamic equations with the corresponding structure-process coupling.By applying the stability-based calculation model about the critical rolling speed in each stand,the system dynamic responses around the critical rolling speed were simulated,and the system eigenvalues which represent instability and characteristic frequencies were figured out.Thereafter,via combining the critical rolling speeds with the system dynamic behavior,a dynamics-based optimization model of rolling schedule for the 5-stand cold tandem system was proposed for the purposes of both the chatter suppression and rolling speed increase.In the optimization model,eight rolling technique parameters(four strip thicknesses and four tensions between the upstream and downstream stands)were taken as design variables,and the constraint conditions were set as no chatter instability in all five stands,and the optimization goal was to maximize the outlet speed of the final stand.The pattern search method was introduced to solve the optimization model.By applying such a dynamics-based optimization model for the 5-stand cold tandem rolling process,the chatter instability was suppressed effectively and the rolling efficiency was improved considerably;therefore,such an optimization model is expected to be valuable for intelligent manufacturing of rolling process.

Effect of roll speed ratio on the texture and microstructural evolution of an FCC high-entropy alloy during differential speed rolling

A very coarse-grained(335μm)Fe_(41)Mn_(25)Ni_(24)Co_(8)Cr_(2)high-entropy alloy with a single FCC phase was cold rolling to a 80%reduction in thickness using the differential speed rolling technique with various speed ratios(SRs)ranging between 1 and 4.As the SR was increased,the volume fraction of the region of high-density micro-shear bands increased to accommodate the higher shear strain.At SR=4,the entire thickness of the sheet was covered with micro-shear bands,and ultrafine(sub)grains with a size of1.4μm were uniformly formed along the shear bands.A continuous dynamic recrystallization(CDRX)mechanism occurred during rolling,and a higher SR accelerated the CDRX process.During conventional rolling(at SR=1),a brass{110}<112>orientation texture with minor components of S{123}<634>and Cu{112}<111>orientations developed.At higher SRs,shear texture developed as the main type,while the development of rolling texture was suppressed.The microstructure at SR=4 obtained after annealing at973 K showed a fully recrystallized microstructure composed of a five times smaller grain size(4μm)with a higher intensity ofγfiber texture compared with that prepared by conventional rolling.The samples processed with high SRs exhibited better tensile properties compared with the conventionally rolled sample in terms of strength and ductility after annealing.The current results demonstrate that by using differential speed rolling with a high SR,one can achieve a significantly finer and more homogeneous microstructure,stronger shear texture,and superior tensile mechanical properties for an FCC high-entropy alloy compared to that obtained by conventional rolling.The strength of the as-rolled and annealed samples was quantitatively explained by considering the contribution of grain size and dislocation density to strengthening.

Microstructure and tensile properties of magnesium nanocomposites fabricated using magnesium chips and carbon black

In this study,carbon black(0,0.01,0.03 and 0.08 wt%)and AZ31(Mg-3Al-lZn)magnesium chips were used to fabricate carbon black-reinforced magnesium matrix composites with extrusion or a combination of extrusion and high-ratio differential speed rolling.After hot pressing at 693 K and extrusion at 623 K with an extrusion ratio of 22,the magnesium chips coated with carbon black were soundly bonded into a bulk composite material.The grain sizes of the extruded materials were similar with a size of 48.2-51.5|im despite the difference in the amount of carbon black.The yield strength and ultimate tensile strength increased from 177 to 191 MPa and from 240 to 265 MPa,respectively,as a result of the addition of 0.01%carbon black;however,a further increase in the strength was marginal with additional carbon black.The same trend was observed in the strain hardening behavior.The tensile elongation increased by to the addition of 0.01%carbon black(from 15.8%to 17.4%)due to the increased work hardening effect,but decreased with additional carbon black due to its agglomeration and poor dispersion at higher concentration.After high-ratio differential speed rolling(HRDSR)on the extruded materials and subsequent annealing,the AZ31 and AZ31 composites had a similar fine grain size of 16.3-17.9 p.m.The annealed HRDSR composites showed the best mechanical properties at a higher content of carbon black(0.03%)compared to that(0.01%)for the extruded composites.This resulted from the enhanced dispersion effect of the carbon black due to the high shear flow induced during the HRDSR process.The extruded composites exhibited the three distinct hardening stages(stage II,stage III and stage IV),while the annealed HRDSR composites mainly displayed the stage III hardening.The addition of carbon black increased the strain hardening rate at all the strain hardening stages in both of the extruded and annealed HRDSR materials.At the initial hardening stage,the strain hardening rates of the extruded composites were higher than those of the annealed HRDSR composites,but this became reversed at the later stage of hardening.Possible explanations for this observation were discussed.The strength analysis suggests that dislocation-carbon black interaction by Orowan strengthening and dislocation generation due to a difference in thermal expansion between matrix and carbon black are the major strengthening mechanisms.

Improvement of the Process of Separation of Cotton Fiber from Seeds

The differential equation, obtained as a result of the theoretical study of the movement of the bare seed on the surface of the grate of the saw gin, made it possible to determine the trajectory of the movement of the seed. The rib is one of the main working bodies of the saw gin. It serves for the free passage of the saw blades through it into the working chamber, for the withdrawal of the fiber caught on the saw teeth after separating it from the seed. A number of studies have been carried out to improve the working elements of the saw gin. The purpose of the research is to create the possibility of timely withdrawal of bare seeds from the working chamber of the saw gin by creating a concavity on the working surface of the grate. The use of the Euler equation for the movement of bare cotton seed along the grate contour, taking into account its speed V, density ρ, pressure P, made it possible to obtain a graph of seed distribution along the grate contour. An experimental 30-saw gin was developed and manufactured, the research carried out on it allowed to determine the rational parameters of new grates, which are recommended for introduction into production. The dependence of the location of the rectilinear part of the general contour on the shape of its convexity and concavity is determined. Based on the above equations, using separate functions, we present the view of the grate profile in the coordinate system modeled on the MAPLE-17 program.

Effect of rare earth elements on the thermal cracking resistance of high speed steel rolls

The effect of rare earth elements on the thermal cracking resistance of high speed steel （HSS） rolls was investigated. Laser rapid heating was used for thermal fatigue experiments. Thermal cracks and microstructure were observed using metalloscopy and scanning electron microscopy. The results showed that thermal cracks initiated from the interface between the matrix and eutectic carbides （including M6C and M7C3 type carbides）,and propagated along the interface between the two phases. MC type carbides enriched with vanadium could prevent the propagation of thermal cracks. The presence of rare earth elements decreased the quantity of big eutectic carbides,and proportionally increased spherical and rod-shaped MC type carbide content. HSS0 （0.00% RE） had approximately three times the thermal cracking density of HSS3 （0.12 wt.% RE）. Rare earth elements were shown to significantly improve the microstructure and thermal cracking resistance of HSS rolls.

Effect of rare earth addition on continuous heating transformation of a high speed steel for rolls

The effect of rare earth（RE） on continuous heating transformation of a high speed steel for rolls was investigated by using differ-ential scanning calorimetry（DSC） with combination of microstructure analysis.Determination of the Ac1 and Ac3,the starting temperature of carbide dissolution and melting upon heating,the enthalpy change for the α→γ transformation and overall carbide dissolution were also es-tablished.It was found that RE could reduce the volume fraction of large eutectic carbides and the chrysanthemum-like eutectic colonies but could not change the phase composition.RE made a little change to Ac1,but the variation in Ac3 and enthalpy for the α→γ followed an in-creasing pattern as the RE addition increased.The start temperatures of carbides dissolution increased with increase of RE addition,which may be associated with the influences of RE on the morphology of carbides,but the overall enthalpy change of carbides dissolution decreases as the RE addition increased.Moreover,the start temperature of melting also increased with increasing RE addition.

Influence of rare earth elements on solidification behavior of a high speed steel for roll using differential scanning calorimetry

The influence of rare earths（RE） on solidification behavior of a high speed steel for roll was investigated by using differential scanning calorimetry（DSC） in combination of microstructure analysis.It was found that the sequence of solidification was L→γ,L→γ＋MC,L→γ＋M2C,L→γ＋M6C,respectively.The start temperature and the latent heat liberated by unit mass of L→γ and L→γ＋MC increased with increase of RE addition,indicating that RE could trigger the crystallization of the primary γ and the MC carbide more effectively.The promoting effect of RE on the heterogeneous nucleation was believed to be an important cause of this effect.Grain refinement,discontinuous network of eutectic carbides and disperse and finer MC were observed in the samples with RE addition,moreover,RES could act as the heterogeneous nucleus of the MC.RE addition was favorable for stable M6C at the expense of the metastable M2C.