Improvement of Temperature Drop Model Parameters for 4200mm/3500mm Rolling of Baosteel Medium and Thick Plate

Based on the temperature situation during the rolling process of 4200 mm/3500 mm medium and thick plates at Baosteel,this article analyzes the influencing factors of temperature changes during the rolling process from the perspective of heat transfer theory and the temperature change law during the rolling process.The temperature loss during the four rolling processes is tracked on site,and the temperature drop model parameters during the rolling process of 4200mm/3500mm medium and thick plates at Baosteel are quantitatively provided.It is applied to actual rolling production and has achieved good results.

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.

Dynamic characteristics of cold rolling mill and strip based on flatness and thickness control in rolling process

The dynamic model of cold rolling mill based on strip flatness and thickness integrated control was proposed,containing the following sub-models:the rolling process model,the dynamic model of rolls along axial direction,and the compensation model.Based on the rule of volume flow rate,the dynamic rolling process model was built.The work roll and backup roll were taken as elastic continuous bodies,the effect of shear and moment of inertia were taken into consideration,and then the dynamic model of rolls was built.The two models were coupled together,and the dynamic model of rolling mill was built.In the dynamic model,the thermal expansion of the rolls,the wear of the rolls and other related parameters can not be considered.In order to compensate the dynamic model,the coupled static model of rolls and strip was applied.Then,according to the inner relationship of these models,the dynamic model and the compensation model were coupled,and the dynamic model of rolling mill based on the strip flatness and thickness integrated control was built.The dynamic simulation of the rolling process was made,and the dynamic thickness and the dynamic flatness information were obtained.This model not only provides a theory basis for the virtual rolling,but also provides a platform for the application of advanced control theory.

Optimization of Holding Temperature and Holding Thickness for Controlled Rolling on Plate Mill

Holding temperature and holding thickness are main parameters for two-phase controlled rolling on plate mill. The optimization of holding temperature and holding thickness for pass schedule calculation of two-phase controlled rolling on plate mill was presented and its feature is as follows： （1） Determination of holding thickness can be automatically obtained based on the influence of mill safety limits, tracking zone length and holding time on holding thickness; （2） Determination of holding temperature can be automatically obtained and the holding time can be reduced as much as possible; （3） Algorithm can modify the holding temperature and thickness depending on slab size and product size.

Dynamic Strip Thickness Simulation on Five-Stand Cold Continuous Rolling Mill

Based on a rolling model, the simulation of strip thickness during cold continuous rolling was made on the platform software Matrix. The simulation system combined the discrete system with continuous system for high speed and dynamics. Simulation parameters were calculated by differential element method, and the simulation results fit in with practical data very well.

Strip Thickness Control of Cold Rolling Mill with Roll Eccentricity Compensation by Using Fuzzy Neural Network

In rolling mill, the accuracy and quality of the strip exit thickness are very important factors. To realize high accuracy in the strip exit thickness, the Automatic Gauge Control (AGC) system is used. Because of roll eccentricity in backup rolls, the exit thickness deviates periodically. In this paper, we design PI controller in outer loop for the strip exit thickness while PD controller is used in inner loop for the work roll actuator position. Also, in order to reduce the periodic thickness deviation, we propose roll eccentricity compensation by using Fuzzy Neural Network with online tuning. Simulink model for the overall system has been implemented using MATLAB/SIMULINK software. The simulation results show the effectiveness of the proposed control.

Effect of variable thickness cross rolling on edge crack and microstructure gradient of AZ31 magnesium alloy

The hot rolling experiment of AZ31 magnesium alloy was carried out by laying anoverlay mold at the initial temperature of 400℃.According to the Mizushima automatic plan view pattern control system(MAS)rolling theory and the cross rolling process,different reductions in the middle and edges of the magnesium alloy were realized,and the influence of the regional controlled reduction rolling on the edge cracks and microstructure gradient of the magnesium alloy were analyzed.It is shown that this rolling approach has reduced the maximum edge crack depth of the rolled piece by 56.85%,and there is a weakening tendency in the base surface texture of the strip edge,the base surface texture density drops from 23.97 to 17.48 after ordinary flat rolling.It exhibits basal texture gradients from the edge to the middle of the sheet along the RD direction,which reflected the uneven deformation of the sheets.It is suitable for the processing of metal molds that require large edge reductions such as mobile phone shells,and provided a theoretical basis for the variable thickness rolling of the magnesium alloy strip.

Influence of a multi-step process on the thickness reduction error of sheet metal in a flexible rolling process

Flexible rolling is a forming process based on thickness reduction, and the precision of thickness reduction is the key factor affecting bending deformation. The major purpose of the present work is to solve the problem of bending deformation error caused by insufficient thickness reduction. Under the condition of different rolling reductions with the same sheet thickness and the same thickness reduction with different sheet thicknesses, the thickness reduction error of sheet metal is analyzed. In addition, the bending deformation of sheet metal under the same conditions is discussed and the influence of the multi-step forming process on the thickness reduction error is studied. The results show that, under the condition of the same sheet thickness, the thickness reduction error increases with increasing rolling reduction because of an increase in work hardening. As rolling reduction increases, the longitudinal bending deformation decreases because of the decrease of the maximum thickness difference. Under the condition with the same thickness reduction, the thickness reduction error increases because of the decrease of the rolling force with increasing sheet thickness. As the sheet thickness increases, the longitudinal bending deformation increases because of the increase in the maximum thickness difference. A larger bending deformation is divided into a number of small bending deformations in a multi-step forming process, avoiding a sharp increase in the degree of work hardening; the thickness reduction error is effectively reduced in the multi-step forming process. Numerical simulation results agree with the results of the forming experiments.

Research and application on the automatic measuring device for testing transverse thickness difference of cold-rolling steel sheet

Many advanced technologies have been applied in developing the automatic measuring device for testing transverse thickness difference of cold-rolling steel sheet,such as the technologies of automatic control,sensor measurement,marking identification,photographic location,computer application and information transmission.This measuring device can measure the transverse thickness difference of the steel plate accurately and quickly,with a high detection level of automation.It is an effective detection equipment for transverse thickness control of steel plate.Horizontal width of steel plate measuring 0.8-1.4 m, horizontal measurement point positioning accuracy±0.02 mm,thickness range 0.2-2.0 mm, measurement accuracy within±1μm.

Formation mechanism and control of aluminum layer thickness fluctuation in embedded aluminum-steel composite sheet produced by cold roll bonding process

The influences of rolling reduction and aluminum sheet initial thickness(AIT)on the thickness fluctuation of aluminum layer(TFA)of embedded aluminum?steel composite sheet produced by cold roll bonding were investigated,the formation mechanism of TFA was analyzed and method to improve the thickness uniformity of the aluminum layer was proposed.The results showed that when the reduction increased,TFA increased gradually.When the reduction was lower than40%,AIT had negligible effect on the TFA,while TFA increased with the decrease of AIT when the reduction was higher than40%.The non-uniformities of the steel surface deformation and the interfacial bonding extent caused by the work-hardened steel surface layer,were the main reasons for the formation of TFA.Adopting an appropriate surface treatment can help to decrease the hardening extent of the steel surface for improving the deformation uniformity during cold roll bonding process,which effectively improved the aluminum thickness uniformity of the embedded aluminum/steel composite sheets.

Hot-rolled strips of up to 19 mm in thickness and their processing to helically welded large diameter pipes of grade X80

Hot-rolled wide strip for production of large diameter,heavy gauged(up to 19 mm) helical line pipe grade X80 was a priority development over the last three years.Microstructure,texture and mechanical properties of strips have been characterised.Also the welding conditions have been simulated.The favourable microstructure is achieved by the proper selection of an appropriate chemical composition of low carbon content and increased niobium micro alloying in combination with suitable strictly controlled hot-rolling parameters.The addition of niobium in combination with the adjustment of other alloying elements increases the recrystallisation stop temperature and thus makes it possible to apply a high temperature processing(HTP) concept.The homogeneous bainitic microstructure across the strip gauge is then formed during accelerated cooling on the run-out table of the hot-rolling mill.All results indicated excellent properties of these hot strips which make it suitable for spiral pipes of grade X80 for example 18.9mm×Φ1 220 mm at dimension.

Parametric analysis of mixed lubrication characteristics in work zone of strip rolling

A theoretical model for mixed lubrication with more accurate contact length has been developed based on the average volume flow model and asperity flattening model,and the lubricant volume flow rate and outlet speed ratio are determined by integrating differential equations based on rolling parameters.The lubrication characteristics at the roll-strip interface with different surface roughness,rolling speed,reduction and lubricant viscosity are analyzed respectively.Additionally,the average volume flow rates of lubricant under different rolling conditions are calculated and used to explain the change rule of lubrication characteristics.The developed scheme is able to determine the total pressure,lubricant pressure,film thickness and real contact area at any point within the work zone.The prediction and analysis of mixed lubrication characteristics at the interface is meaningful to better control the surface quality and optimize the rolling process.

Optimal Control of a Tandem Cold Rolling System for Tracking Problem

The optimal control principle and procedure of a tandem cold rolling system for tracking problem have been proposed in this paper for the first time. The state-space description of the tandem cold rolling system for the cold-strip mill of Wuhan Iron and Steel Company is: x_(k+1)=Ax_k+(_k,y_k=Cx_k+η_k The optimum performance index of the system for tracking problem is: J_(min)=minEr[(1/2)sum from k=0 to m e'_kOe_k sum from k=0 to m-1 u'_kRu_k] The authors have deduced the optimal control of the system for tracking problem as follows u_k~*=-S_k(Ay_k+_(k+1)-) the feedback gain matrix S_k is given by S_k=(B'P_(k+1)B-R)^(-1)B'P_(k+1) Pk satisfies the matrix difference equation p_k=P_(k+1)-[(S_k^(-1))'-B']^(-1)R(S_k^(-1)-B)^(-1)+Q with terminal condition P_m=Q. On the above-mentioned principle of optimal control,an optimal control procedure of the tandem cold rolling system has been obtained, and a computer simulation has been performed. The results of the simulation are satisfactory.

SURFACE ROUGHNESS EFFECTS IN ALUMINIUM ROLLING

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Transverse thickness difference control technology for non-oriented silicon steel

Transverse thickness difference is an important quality index of non-oriented silicon steel strips. In order to fulfill users＇ accuracy requirements on the transverse thickness of silicon steel and improve the production yield, the factors influencing transverse thickness difference were analyzed. Then the work roll shape, control strategy and incoming hot-rolled strips were optimized. Since the optimization measures were implemented in the actual production, the thickness difference of non-oriented silicon steel has been reduced greatly and fulfilled the requirements placed by users. These measures have achieved remarkable effects.

Theory research on use efficiency of emulsion in cold rolling

Lubrication in cold rolling process is used not only to control friction,but also to control surface quality and thermal chamber.Successful cold rolling of strip at high speeds requires an optimum presence of lubricant film thickness at the contact.In order to have a better control on rolling process the awareness for the prediction and maintenance of desired minimum film thickness.On the basis of learning and summarizing the theories early founded by experts around the world,this paper constructed the mixed lubrication model. This paper investigated the lubrication state variation caused by oil and rolling condition differences by cold rolling experiments.The experiments indicated that oil has a big influence to rolling process,and rolling speed directly influence the lubrication state.

Simulation Analysis and Optimization of Rolling Process of Steel Rim

In order to solve the problems of rolling forming accuracy and fillet thinning of alloy steel rim, a three-dimensional model of three pass rolling process was established, and the influence of different process parameters on forming quality was analyzed by using the finite element software, and the optimal process parameter combination was obtained. On this basis, the simulation results of wheel rim stress and strain for each pass rolling are analyzed, and the particle tracking technology is introduced to analyze the variation rule of stress in each incremental step. Finally, the simulation and experimental results show that the simulation thickness is basically consistent with the actual thickness, which improves the accuracy of rim rolling forming, and further verifies the correctness of rolling process simulation.

Unsteady lubrication modeling of inlet zone in metal rolling processes

An unsteady lubrication model of inlet zone in metal rolling was established. The simulation computations show that for the variation amplitude of the inlet film thickness, the variation of the inlet angle contributes the largest, the surface mean speed contributes the second and the back tension stress the least. The higher the input frequency is, the smaller the amplitude output of the inlet film thickness will be. For a sinusoidal input, the inlet film thickness varies periodically but is not a sine wave because the system is not linear.

考虑弹头滚转姿态变化影响的防热层厚度优化

基于气动热/结构温度响应耦合计算方法,研究了弹头固定攻角再入条件下锥身典型子午面结构温度响应特性,以及滚转姿态变化时刻对各子午面结构温度响应的影响,建立了考虑弹头滚转姿态变化影响的防热层厚度优化方法,并基于该方法开展了弹头防热层厚度优化。最后,研究了滚转姿态变化次数对优化效果的影响。结果表明:在再入弹道前段进行滚转姿态变化可使外壁面气动加热量更为合理,有效降低弹体锥身壳体内壁面温升。当迎、背风面壳体内壁面最大温升约束为25 K时,与无滚转姿态变化状态下相比,滚转姿态变化设计可使防热层厚度减小0.725 mm,减小幅度为5.4%。通过与滚转姿态变化时刻的联合设计可有效降低锥身防热层厚度。与单次滚转姿态变化时相比,两次滚转姿态变化时防热层厚度减小量仅增大1.9%,增加滚转姿态变化次数对优化效果影响较小。

高性能高精度铜合金带材六辊冷轧机组的研发与应用

针对高性能高精度铜带材生产的技术难点,首次开发了800 mm小辊径六辊可逆中精轧机组。介绍了机组的工艺设备组成、主要工艺技术参数配置和装机水平;重点阐述了开发的新技术:紧凑式弯辊小辊径六辊轧机、高精度自动厚度控制技术、高精度板形自动控制系统以及高效除油装置。机组投入使用后,产品质量得到有效提高,对于厚度为0.175 mm,宽度为620 mm的铜带,成品厚差不大于±1μm,板形均方差不大于0.55I。