Prediction and Analysis of the Force and Shape Parameters in Variable Gauge Rolling

Variable gauge rolling is a new process to obtain a plate for which the thickness changes continuously by continuously and dynamically adjusting the roll gap upward and downward in the rolling process.This technology is an efective method for producing lightweight,low-cost,and economical plates.However,variable gauge rolling is an unsteady process,and the changes in the force and deformation parameters are complex.In this research,based on the minimum energy theory of the variational principle and considering the characteristics of the roll movement and workpiece deformation comprehensively,the internal plastic deformation,friction,shear and tension powers,and the minimum result of the total power functional in upward and downward rolling are obtained with the frst integral and then with a variation of adopting the specifc plastic power and strain rate vector inner product.The analytical results of the deformation and force parameters are also established using the variational method.Then the precision of this model is certifed using the measured values in a medium plate hot rolling plant and the experimental data for Tailor Rolled Blank rolling.Good agreement is found.Additionally,the variation rule of bite angle,neutral angle,and location neutral points are shown,and the change mechanism of the friction parameter on the stress state efect coefcient is given in variable gauge rolling.This research proposes a new mathematical model for rolling process control that provides a scientifc basis and technical support for obtaining an accurate section shape in variable gauge rolling production.

Mathematical modeling of thermo-mechanical behavior of strip during twin roll casting of an AZ31 magnesium alloy

The effect of set-back distance on the thermo-mechanical behavior of the strip during twin roll casting(TRC)of an AZ31 magnesium alloy was modeled using finite element method(FEM).Model validation was done by comparing the predicted and measured exit strip surface temperature as well as the secondary dendrite arm spacing(SDAS)through the thickness of the sheet to those measured during experiments.Model results showed as the set-back distance increases,the strip exit temperature decreases and the solidification front moves toward the entry of the roll gap.The cast strip also experiences more plastic deformation and consequently,the normal stress on the strip surface and effective strain at the strip center-line increase.Moreover,higher separating forces were predicted for longer set-back distances.Model predictions showed that changing the set-back distance by varying the final thickness has a more significant effect on the temperature and stress-strain fields than altering the nozzle opening height.

Ground roll separation method via threshold fi ltering and constraint of seismic wavelet support in curvelet domain

Most traditional ground roll separation methods utilize only the difference in geometric characteristics between the ground roll and the refl ection wave to separate them.When the geometric characteristics of data are complex,these methods often lead to damage of the reflection wave or incompletely suppress the ground roll.To solve this problem,we proposed a novel ground roll separation method via threshold filtering and constraint of seismic wavelet support in the curvelet domain;this method is called the TFWS method.First,curvelet threshold fi ltering(CTF)is performed by using the diff erence of the curvelet coeffi cient of the refl ection wave and the ground roll in the location,scale,and slope of their events to eliminate most of the ground roll.Second,the degree of the local damaged signal or the local residual noise is estimated as the local weighting coeffi cient.Under the constraints of seismic wavelet and local weighting coeffi cient,the L1 norm of the refl ection coeffi cient is minimized in the curvelet domain to recover the damaged refl ection wave and attenuate the residual noise.The local weighting coeffi cient in this paper is obtained by calculating the local correlation coeffi cient between the high-pass fi ltering result and the CFT result.We applied the TFWS method to simulate and fi eld data and compared its performance with that of frequency and wavenumber filtering and the CFT method.Results show that the TFWS method can attenuate not only linear ground roll,aliased ground roll,and nonlinear noise but also strong noise with a slope close to the refl ection events.

Recovery of Cassiterite and Topaz Minerals from an Old Metallurgical Dump, Eastern Desert of Egypt

Huge amounts of tailing dumps as a result of mines’ blasting operations were impacting economic and environmental problems. Evaluation of one of these tailing dumps of the Eastern Desert of Egypt showed the presence of reasonable amount of cassiterite mineral reaching 0.199% SnO2. The mineral cassiterite was found as finely disseminated particulates, reached to 5 microns, within varieties of quartz-feldspar-hornblende-biotite granitic formations. In the present study, the processing regime considered from the beginning the alignment between reaching cassiterite mineral liberation size, and its extreme brittleness character. Stirring ball milling technique was applied to produce −0.51 mm product with minimum fines as possible, which was left aside for a separate study. The ground product −0.51 + 0.074 mm was subjected to joint shaking table/dry high intensity magnetic separation techniques after splitting it into two fractions, −0.51 + 0.21 mm and −0.21 + 0.074 mm. Each fraction was separately subjected to “Wilfley” shaking table. At optimum conditions, a shaking table concentrate was obtained with 0.29% SnO2 and an operational recovery reached 96.94% from a feeding contained 0.19% SnO2. The heavies and the two middling products after shaking table were directed separately after dryness to dry high intensity magnetic separation using “Eriez” rare earth roll separator, meanwhile the light fractions were rejected. Mathematically designed experiments were applied to optimize the separation process. At optimum conditions, a final cassiterite concentrate was obtained with 11.25% SnO2, and an operational recovery 94.08%. In addition, a topaz mineral concentrate was separated at splitter angle 65˚.

Rolling With Simplified Stream Function Velocity and Strain Rate Vector Inner Product

The dual-stream function velocity field is reduced in order to analyze two-dimensional plate broadside roll- ing in roughing. The strain rate vector inner product and integral mean value theorem, as well as coqine vector inner product are used respectively in plastic deformation power, friction losses and shear power. A theoretical solution of roll torque and separating force for the rolling is obtained and the calculated results by the solution are compared with those measured in broadside rolling on-line. It shows that both the force and torque calculated are higher than those of measured, but the maximum relative error between them is no more than 11%.

Linear Integral Analysis of Bar Rough Rolling by Strain Rate Vector

A new linear integral method for bar hot rolling on roughing train was obtained. First, for plastic deformation energy rate, equivalent strain rate about Kobayashi＇s three-dimensional velocity field was expressed by two-dimensional strain rate vector; then, the two-dimensional strain rate vector was inverted into inner product and was integrated term by term. During those processes, boundary equation and mean value theorem were introduced; for friction and shear energy dissipation rate, definite integral was applied to the solution process. Sequentially, the total upper bound power was minimized, and the analytical expressions of rolling torque, separating force, and stress state factor were obtained. The calculated results by these expressions were compared with those of experimental values. The results show that the new linear integral method is available for bar rough rolling analysis and the calculated results by this method are a little higher than those of experimental ones. However, the maximum error between them is less than 10%.

Recovery of Total Heavy Minerals from Badlands of Basanputti Village,Odisha

The badland topography of Basanputti Village, Ganjam District, Odisha, possesses red sediments. The typical red sediment deposit, on average, consists of 71.8% total heavy minerals （THM）, out of which 62.1% are ilmenite. The other heavy minerals sillimanite, zircon, garnet, monazite, and pyriboles are in the order of abundance identified. In this present study, Mozley mineral separator has been used to recover THM from red sediment. Mineral separator results indicate that a product ob- tained contains 72.2% by weight with 94.4% THM and 95% recovery. The ilmenite concentrate recov- ered using dry low-intensity magnetic separator from the THM concentrate can be used in pigment in- dustries after suitable pyrometallurgical/chemical processing methods.