STUDY OF ROLLING FORCE DISTRIBUTION ALONG THE ROLLING OF PAIR CROSS MILL

The theory of three-dimensional deformation is used.Based on rigid plastic assumption, the theory of stick friction and the sheet crown curve at the entry and the exit are used. The mathematical analytical formula of the rolling force in lateral distribution is deriven.

Force Parameter Model of 3-Roll Mills for Continuous Cold Rolling Wires

Based on experimental data, the mathematical model of rolling force parameters of 3-roll mills was studied. The structure ofthe model was theoretically set up and the coefficients were determined by static analysis of the data. The torque in continuous rollingwas measured, and the characteristics and efficiency of 3-roll mills are investigated.

Accuracy improvement of the traditional rolling force and torque model powered by an industrial data platform

The calculation results of the rolling force and torque model based on Orowan's differential equation numerical solution method do not fit with the industrial measurements very well.In particular,a quite large deviation on the torque model was found.On the basis of analyzing the shortcomings of the existing method,an improved rolling force and torque model algorithm aided by the Process Integrated Data Application System platform is proposed.Accordingly,the calculation accuracy of the rolling torque model is improved.The improved models are verified by 1711136 records of a data platform.The improved models are also based on Orowan's differential equation.Two coefficients,namely,friction factor and forward slip,are recognized as the crucial factors to be determined from industrial measurements to improve the accuracy.Therefore,the proposed method is a hybrid method that can be used to deeply understand the rolling process and improve the model's accuracy by combining traditional plastic mechanics and data-driving global optimization algorithms.This paper proposes a new approach to studying theoretical rolling deformation models powered by the industrial data platform.

A Model to Predict Rolling Force of Finishing Stands with RBF Neural Networks

In view of intrinsic imperfection of traditional models of rolling force, in ord er to improve the prediction accuracy of rolling force, a new method combining radial basis function(RBF) neural networks with traditional models to predict rolling f orce was proposed. The off-line simulation indicates that the predicted results are much more accurate than that with traditional models.

MENDED GENETIC BP NETWORK AND APPLICATION TO ROLLING FORCE PREDICTION OF 4-STAND TANDEM COLD STRIP MILL

In order to make good use of the ability to approach any function of BP (backpropagation) network and overcome its local astringency, and also make good use of the overallsearch ability of GA (genetic algorithms), a proposal to regulate the network's weights using bothGA and BP algorithms is suggested. An integrated network system of MGA (mended genetic algorithms)and BP algorithms has been established. The MGA-BP network's functions consist of optimizing GAperformance parameters, the network's structural parameters, performance parameters, and regulatingthe network's weights using both GA and BP algorithms. Rolling forces of 4-stand tandem cold stripmill are predicted by the MGA-BP network, and good results are obtained.

Dynamic Correction Algorithm of Rolling Force in Plate Rolling

Based on the Shougang plat mill project, an on-line dynamic correction algorithm was analyzed. This algorithm can adjust model coefficients better because the reasonable correction is based on the measured and calculated rolling force. The results of application on site show that this on-line dynamic correction algorithm is effective.

Application of cluster analysis on optimization of rolling force learning

The rolling force learning function is an important part of the hot strip parameter calculation process, and the steel classification is the basis of the model parameter calculation,which has a direct impact on the model calculation precision,and the classification of steel quality will directly affect the accuracy of the model calculation.This paper is for the classification of a certain type of steel,in order to find the optimal classification of steel model to achieve greater precision of the rolling force set.Cluster analysis is a method for the study of affinities between samples or variables,in which Distance Coefficient method can be used to demonstrate the differences between the equivalent measured values of the steel deformation resistance in hot strip rolling.Based on the characteristics of the steel components the composition calculation formula CEQ is created by the trial and error method,so as to achieve the consistency between the CEQ and the equivalent deformation resistance by cluster analysis,that is the composition calculation formula CEQ can be used to characterize the equivalent deformation resistance of the steel in hot rolling.In the actual production process,through the composition formula CEQ,the classification of the steel is made,by which the steel rolling force learning calculation is classified and the rolling force setup deviation is reduced,the rolling stability is improved.

Model of Aluminium Foil Rolling Force Based on Neural Networks

Based on the principle of BP neural networks, the rolling force model is established after thoroughly analyzing and reprocessing the data of 1 350 mm aluminium foil mill. It states that the difference between the output of artificial neural networks rolling force model and the real value is in the order of 3 percent. The model reflects the real feature of process.

Reshaping force for deformed casing repairing with hydraulic rolling reshaper and its influencing factors

Hydraulic rolling reshaper is an advanced reshaping tool to solve the problem of casing deformation,which has been widely used in recent years.When it is used for well repair operation,the reshaping force provided by ground devices is generally determined by experience.However,too large reshaping force may destroy the deformed casing,and too small reshaping force may also prolong the construction period and affect the repairing effect.In this paper,based on Hertz contact theory and elastic-plastic theory,combined with the process parameters of shaping,and considering the structural characteristics of the deformed casing and reshaper,we propose a mathematical model for calculating the reshaping force required for repairing deformed casing by hydraulic rolling reshaper.Meanwhile,the finite element model and numerical method of hydraulic rolling reshaper repairing deformed casing are established by using the finite element method,and the reliability of the mathematical model is verified by several examples.On this basis,the control variable method is used to investigate the influence of each parameter on the reshaping force,and the influence degree of each parameter is explored by orthogonal simulation test and Pearson correlation analysis.The research results not only provide an important theoretical basis for the prediction of reshaping force in on-site construction,but also provide a reference for the subsequent improvement of the shaping process.

An analytical model of hot rolling force for a thick plate by combining globally optimal approximation yield criterion and egg-circular velocity field

For the sake of solving the problem that it is difficult to be integrated for the Mises specific plastic power due to its nonlinearity,a new linear criterion,named the globally optimal approximation criterion,is constructed by the polygonal approximation to the Mises circle.The new criterion is proved to be the linear function of the principal stress componentsσ1,σ2 andσ3 and the trajectory of it on theπ-plane is a non-equiangular but equilateral dodecagon intersecting the Mises circle.The theoretical results of the current criterion described by the Lode stress parameters are in excellent accordance with the experimental results.Meanwhile,according to the trend that the metallic flow velocity between rollers aggrandizes gradually from the inlet to the outlet during the hot rolling of a thick plate,a biomimetic velocity field is proposed in which the horizontal velocity component fits the egg-circular curve distribution.The velocity field and its simulated results agree quite well.Subsequently,using the determined linear criterion,energy analysis of the constructed velocity field is utilized to obtain the interior deformation power,while the vector decomposition approach is utilized to obtain the frictional power and shear power.On this basis,the overall power is obtained and the analytical solutions are generated for the rolling torque,rolling force and the coefficient of the stress state under different egg curves by minimizing the neutral angle.Furthermore,the parameter optimization of the characteristic parameterρwhich affects the slope of the egg-circular curve is carried out and the best egg-circular curve which can minimize the energy consumption is determined.The best agreement between the theoretical and observed values of rolling force and rolling torque is under this curve,and the mean relative errors of the rolling torque and rolling force are no more than 2.93%,while the maximum error is no more than 8.35%.

Research progress and intelligent trend of accurate modeling of rolling force in metal sheet

The rolling force model is the basis for reasonable selection of rolling equipment and optimization of rolling process,and the establishment of an accurate mathematical model as well as doing the corresponding parameter analysis has been the focus of research in this field for many years.Different modeling methods of the rolling force and their research progress were introduced,the main methods of which are the theoretical analysis,the finite element simulation,the artificial neural network modeling,the hybrid modeling of theory and neural network,as well as the hybrid modeling of finite element and neural network.Meanwhile,the application examples of rolling force models in thickness control,strip crown control,and schedule optimization were presented,and an outlook on the new directions of future development was made,including establishing new type of hybrid models,solving the black box problem,and realizing the multi-objective optimization accounting for some special requirements.

Influence of Non-Uniform Temperature Distribution on Metallic Charge Length on Energy and Force Parameters During Groove-Rolling

Change in the temperature of band over its length, associated with the stock being non-uniformly heated in the furnace, influences the variations in the magnitudes of energy-force parameters. Using the FEM (Finite Element Model) programs for the computation of the values of the energy-force parameters can take into account the distribution of temperature over the band length. The mathematical model of the computer program Forge2008 was used to theoretically examine the energy-force parameters and plastic metal flow in the roughing stands of the continuous rolling mill. The results of experimental investigation of influence of the non-uniform temperature distribution were presented on the metallic charge length on the energy and force parameters and dimensions of the band during round bars rolling. Thermovision monitoring energy and force parameters monitoring were carried out in continuous rolling mill D350 in one of the Polish industrial plants. On the basis of obtained results, it could be stated that non-uniform distribution of temperatures along the charge length causes local increase of energy and force parameters values and also such distribution affects the local increase of the width of rolled band. The rolling process of charge with non-uniform distribution of temperature could lead to exceeding required dimensional tolerances of the final products.

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.

Establishment of Optimal Blade Clearance of Stainless Steel Rolling-Cut Shear and Test of Shearing Force Parameters

The purpose aims to improve the plate shearing section quality and metal yield by means of optimal blade clearance adjustment model of rolling-cut shear and accurate calculation of the maximum shearing force , as well as for the system optimization design , structure optimization design to provide important basis.A 3 500mm rolling shear of a large stainless steel factory was taken as the test object , and the blade clearance under different influence factors of the clearance value and the shearing section were tested.The optimized production accumulated data regression analysis and the rolling shear process of stainless steel shear test.The test results show that the optimal blade clearance adjustment module is a comprehensive function , which include steel plate thickness , material , temperature and shear plate volume.The shear stress at starting stage with the relative penetration depth increases affected by the above factors , and the fracture peak decreases rapidly after being cut into the roll phase constant.

Rolling Force and Rolling Moment in Spline Cold Rolling Using Slip-line Field Method

Rolling force and rolling moment are prime process parameter of external spline cold rolling. However, the precise theoretical formulae of rolling force and rolling moment are still very fewer, and the determination of them depends on experience. In the present study, the mathematical models of rolling force and rolling moment are established based on stress field theory of slip-line. And the isotropic hardening is used to improve the yield criterion. Based on MATLAB program language environment, calculation program is developed according to mathematical models established. The rolling force and rolling moment could be predicted quickly via the calculation program, and then the reliability of the models is validated by FEM. Within the range of module of spline m=0.5-1.5 mm, pressure angle of reference circle α=30.0°-45.0°, and number of spline teeth Z=19-54, the rolling force and rolling moment in rolling process （finishing rolling is excluded） are researched by means of virtualizing orthogonal experiment design. The results of the present study indicate that： the influences of module and number of spline teeth on the maximum rolling force and rolling moment in the process are remarkable; in the case of pressure angle of reference circle is little, module of spline is great, and number of spline teeth is little, the peak value of rolling force in rolling process may appear in the midst of the process; the peak value of rolling moment in rolling process appears in the midst of the process, and then oscillator weaken to a stable value. The results of the present study may provide guidelines for the determination of power of the motor and the design of hydraulic system of special machine, and provide basis for the farther researches on the precise forming process of external spline cold rolling.

High Precision Prediction of Rolling Force Based on Fuzzy and Nerve Method for Cold Tandem Mill

The rolling force model for cold tandem mill was put forward by using the Elman dynamic recursive network method,based on the actual measured data.Furthermore,a good assumption is put forward,which brings a full universe of discourse self-adjusting factor fuzzy control,closed-loop adjusting,based on error feedback and expertise into a rolling force prediction model,to modify prediction outputs and improve prediction precision and robustness.The simulated results indicate that the method is highly effective and the prediction precision is better than that of the traditional method.Predicted relative error is less than ±4%,so the prediction is high precise for the cold tandem mill.

Theoretical and Experimental Research on Rolling Force for Rail Hot Rolling by Universal Mill

For rail rolling by universal mill, a simplified three-dimensional theoretical model was built firstly. The kinematically admissible velocity field of the web, head, and base of rail was determined respectively; moreover, the corresponding strain rate field and the strength of shear strain rate were obtained. Then, the plastic deformation power of corresponding deformation zone, the power consumed on the velocity discontinuity surface, and the power generated by backward slip and forward slip were proposed. According to the upper-bound method, the roiling force of horizontal roll and two vertical rolls could be obtained. For verifying the theoretical model, the universal rolling experiments of 18 kg/m light rail was accomplished in Yanshan University Rolling Laboratory, and the experimental data of 60 kg/m heavy rail universal rolling were obtained from the Anshan Iron and Steel Group Corporation. Compared with the experimental data, the theoretical results of rolling force for 18 kg/m light rail and 60 kg/m heavy rail universal rolling were somewhat greater than experimental data, but in general did not exceed them by 15%. Thus, the simplified model was reliable and feasible for presetting and optimizing the parameters of rolling technology according to the upper-bound method.

Long-and Short-Term Self-Learning Models of Rolling Force in Rolling Process Without Gaugemeter of Plate

Owing to a lack of gaugemeter and the variety of steel grades and standards in some plate mills, the longand short-term self-learning models of rolling force based on gauge soft-measuring with high precision were brought up. The soft-measuring method and target value locked method were used in these models to confirm the actual exit gauge of passes, and thick layer division and exponential smoothing method were used to dispose the deformation resistance parameter, which could be calculated from the actual data of the rolling process. The correlative mathematical methods can also be adapted to self-learning with gaugemeter. The models were applied to the process control system of AGC （automatic gauge control） reconstruction on 2800 mm finishing mill of Anyang steel and favorable effect was obtained.

Preset model of bending force for 6-high reversing cold rolling mill based on genetic algorithm

The hydraulic roll-bending device was studied, which was widely used in modem cold rolling mills to regulate the strip flatness. The loaded roll gap crown mathematic model and the strip crown mathematic model of the reversing cold rolling process were established, and the deformation model of roll stack system of the 6-high 1 250 mm high crown （HC） reversing cold rolling mill was built by slit beam method. The simulation results show that, the quadratic component of strip crown decreases nearly linearly with the increase of the work roll bending force, when the shifting value of intermediate roll is determined by the rolling process. From the first pass to the fifth pass of reversing rolling process, the crown controllability of bending force is gradually weakened. Base on analyzing the relationship among the main factors associated with roll-bending force in reversing multi-pass rolling, such as strip width and rolling force, a preset mathematic model of bending force is developed by genetic algorithm. The simulation data demonstrate that the relative deviation of flatness criterions in each rolling pass is improved significantly and the mean relative deviation of all five passes is decreased from 25.1% to 1.7%. The model can keep good shape in multi-pass reversing cold rolling process with the high prediction accuracy and can be used to guide the production process.

Cast-rolling force model in solid-liquid cast-rolling bonding(SLCRB) process for fabricating bimetal clad strips

Based on twin-roll casting, a cast-rolling force model was proposed to predict the rolling force in the bimetal solid-liquid cast-rolling bonding(SLCRB) process. The solid-liquid bonding zone was assumed to be below the kiss point(KP). The deformation resistance of the liquid zone was ignored. Then, the calculation model was derived. A 2D thermal-flow coupled simulation was established to provide a basis for the parameters in the model, and then the rolling forces of the Cu/Al clad strip at different rolling speeds were calculated. Meanwhile, through measurement experiments, the accuracy of the model was verified. The influence of the rolling speed, the substrate strip thickness, and the material on the rolling force was obtained. The results indicate that the rolling force decreases with the increase of the rolling speed and increases with the increase of the thickness and thermal conductivity of the substrate strip. The rolling force is closely related to the KP height. Therefore, the formulation of reasonable process parameters to control the KP height is of great significance to the stability of cast-rolling forming.