Research and Application of Non-symmetrical Roll Bending Control of Cold Rolling Mill

The existing research of the flatness control for strip cold rolling mainly focuses on the calculation of the optimum adjustment of individual flatness actuator in accordance with the flatness deviation, which can be used for general flatness control. However, it does not work for some special rolling processes, such as the elimination of ultra single side edge-waves and the prevention of strip break due to tilting roll control overshooting. For the purpose of solving these problems, the influences of non-symmetrical work roll bending and intermediate roll bending on flatness control were analyzed by studying efficiencies of them. Moreover, impacts of two kinds of non-symmetrical roll bending control on the pressure distribution between rolls were studied theoretically. A non-symmetrical work roll bending model was developed by theoretical analysis in accordance with practical conditions. The model was applied to the revamp of a 1250 6-H reversible universal crown mill (UCM) cold mill. Theoretical study and practical applications show that the coordination utilization of the non-symmetrical work roll bending control and tilting roll control was effective in flatness control when there appeared bad strip single side edge waves, especially when the incoming strip was with a wedge shape. In addition, the risk of strip break due to tilting control overshooting could be reduced. Furthermore, the non-symmetrical roll bending control can reduce the extent of uneven distribution of pressure between rolls caused by intermediate roll shifting in flatness control and slow down roll wear. The non-symmetrical roll bending control technology has important theoretical and practical significance to better flatness control.

Fuzzy Control System of Hydraulic Roll Bending Based on Genetic Neural Network

For nonlinear hydraulic roll bending control, a new fuzzy intelligent control method was proposed based on the genetic neural network. The method taking account of dynamic and static characteristics of control system has settled the problems of recognizing and controlling the unknown, uncertain and nonlinear system successfully, and has been applied to hydraulic roll bending control. The simulation results indicate that the system has good performance and strong robustness, and is better than traditional PID and neural-fuzzy control. The method is an effective tool to control roll bending force with increased dynamic response speed of control system and enhanced tracking accuracy.

Bending analysis and control of rolled plate during snake hot rolling

In order to study the bending behavior of aluminum alloy 7050 thick plate during snake hot rolling, several coupled thermo-mechanical finite element(FE) models were established. Effects of different initial thicknesses, pass reductions, speed ratios and offset distances on the bending value of the plate were analyzed. ‘Quasi smooth plate' and optimum offset distance were defined and quasi smooth plate could be acquired by adjusting offset distance, and then bending control equation was fitted. The results show that bending value of the plate as well as the extent of the increase grows with the increase of pass reduction and decrease of initial thickness; the bending value firstly increases and then keeps steady with the ascending speed ratio; the bending value can be reduced by enlarging the offset distance. The optimum offset distance varies for different rolling parameters and it is augmented with the increase of pass reduction and speed ratio and the decrease of initial thickness. A proper offset distance for different rolling parameters can be calculated by the bending control equation and this equation can be a guidance to acquire a quasi smooth plate. The FEM results agree well with experimental results.

Modeling and Simulation of Hydraulic Roll Bending System Based on CMAC Neural Network and PID Coupling Control Strategy

The hydraulic roll bending control system usually has the dynamic characteristics of nonlinearity, slow time variance and strong outside interference in the roiling process, so it is difficult to establish a precise mathemati- cal model for control. So, a new method for establishing a hydraulic roll bending control system is put forward by cerebellar model articulation controller （CMAC） neural network and proportional-integral-derivative （PID） coupling control strategy. The non-linear relationship between input and output can be achieved by the concept mapping and the actual mapping of CMAC. The simulation results show that, compared with the conventional PID control algo- rithm, the parallel control algorithm can overcome the influence of parameter change of roll bending system on the control performance, thus improve the anti jamming capability of the system greatly, reduce the dependence of con- trol performance on the accuracy of the analytical model, enhance the tracking performance of hydraulic roll bending loop for the hydraulic and roll bending force and increase system response speed. The results indicate that the CMAC-P1D coupling control strategy for hydraulic roll bending system is effective.

Principle and theoretical analysis of continuous roll forming for three-dimensional surface parts

Continuous roll forming(CRF) is a novel forming process for three-dimensional surface parts,in which a pair of bendable forming rolls is used as sheet metal forming tool.By controlling the gap between the upper and lower forming rolls,sheet metal is non-uniformly extended in the longitudinal direction while it is bent in the transverse direction during the rolling process.As a result,longitudinal bending is gained and a doubly curved surface is formed.With the rotations of the forming rolls,the sheet metal is deformed consecutively,and a three-dimensional surface part is shaped continuously.In this paper,the mechanism of the three-dimensional surface formation in CRF is set forth.Through theoretical analysis of the CRF process,the governing equations for the bending deformation in rolling process are presented.Based on the simplification on the deformation and material model,the formulation to calculate the longitudinal bending deformation is derived,and the methods to design the compression ratio and the roll gap are given,the effects of compression ratio of rolling and the width of blank sheet on the longitudinal bending curvature are analyzed.The forming experiments on typical surface parts and measured results show that forming results with good precision can be obtained by CRF process.