Three-Dimensional Thermo-mechanical Coupled FEM Simulation for Hot Continuous Rolling of Large-Diameter Mandrel Bar

Based on the important boundary conditions of rolling simulation including friction, heat conduction and interactionsof the workpiece and rolls, the hot continuous rolling processes of large-diameter mandrel round bar (200 mm indiameter) in 6VH-stand hot tandem mill are successfully simulated by three-dimensional coupled thermomechanicalelastoplastic finite element method (FEM). The distributions of stress, strain, temperature and the rolling force andtorque for the two-pass and four-pass continuous rolling are calculated respectively. Thus, the two and four-passroll schedules are verified, respectively. The simulation results show that it is safe to produce 200 mm round barby the two-pass (oval pass and round pass) continuous rolling on the existing equipment compared to the four-passcontinuous rolling. There are concave surfaces and increased widths occurring at the end of rolled billet due touneven deformations between the outside and inside of the workpiece as well as the free spreading close to the rollgap of the final pass.

Continuous FEM simulation of multi-pass plate hot rolling suitable for plate shape analysis

In order to continuously simulate multi-pass plate rolling process,a 3-D elastic hollow-roll model was proposed and an auto mesh-refining module with data passing was developed and integrated with FE software,Marc.The hollow-roll model has equivalent stiffness of bending resistance and deformation to the real solid and much less meshes,so the computational time is greatly reduced.Based on these,the factors influencing plate profile,such as the roll-bending force,initial crown,thermal crown and heat transfer during rolling and inter-pass cooling can be taken into account in the simulation.The auto mesh-refining module with data passing can automatically refine and re-number elements and transfer the nodal and elemental results to the new meshes.Furthermore,the 3-D modeling routine is parametrically developed and can be run independently of Marc pre-processing program.A seven-pass industrial hot rolling process was continuously simulated to validate the accuracy of model.By comparison of the calculated results with the industrial measured data,the rolling force,temperature and plate profile are in good accordance with the measured ones.

Complete Mill Simulation of the Rolling Process of 1660 mm Hot Strip Continuous Mills

The three-dimensional plastic deformations of strip are analyzed using the stream surface strip element method, the elastic deformations of rolls are analyzed using the influence coefficient method, the analyzing and computing model of shape and crown of 4-high mill was established by combining them, and the rolling process of 1660 mm hot strip continuous mills was simulated. The simulated results tally well with the experimental results. The modei and the method for simulation of shape analysis and control of hot strip mills were provided.

Two-dimensional Model of the Microstructural Evolution in Hot-strip Rolling Processes of C-Mn Steels by Computer Simulations

In the present paper,the two-dimensional comprehensive model,which integrates the temperature model developed by the authors using finite difference methods and microstructural evolution model,has been developed.By using different microstructural evolution equations developed by Sellars,Senuma et al.and Easka et al.,the comparison studies have been made,which present that (1) the calculated γ-grain sizes show good agreements with the measured;(2) these equations show consistencies at the end of finishing stands.

3D FE Analysis of Thermal Behavior of Billet in Rod and Wire Hot Continuous Rolling Process

An FE model was developed to study thermal behavior during the rod and wire hot continuous rolling process. The FE code MSC. Marc was used in the simulation using implicit static arithmetic. The whole rolling process of 30 passes was separated and simulated with several continuous 3D elastic-plastic FE models. A rigid pushing body and a data transfer technique were introduced into this model. The on-line experiments were conducted on 304 stainless steel and GCr15 steel hot continuous rolling process to prove the results of simulation by implicit static FEM. The results show that the temperature results of finite element simulations are in good agreement with experiments, which indicate that the FE model developed in this study is effective and efficient.

Static and dynamic finite element analysis of 304 stainless steel rod and wire hot continuous rolling process

Three-dimensional finite element models were developed to analyze 304 stainless steel rod and wire hot continuous rolling process with the help of MSC.Marc software. The entire 30-pass deformation process and the actual parameters of production line were taken into account. Static and dynamic procedures were used to study the continuous rolling process with the aid of the thermo-mechanical coupled FEM of elastic-plasticity. The properties of billets, such as deformation, temperature field and rolling force, were mainly discussed. The simulation results of temperature agree well with the measured values. Comparisons of the analysis results obtained using static implicit method and dynamic implicit method were presented. It is shown that static implicit procedure is more accurate than dynamic implicit procedure and is able to simulate the rolling process with a lower speed, such as a roughing mill. Whereas, dynamic analysis shows a higher efficiency than static analysis and is fit for simulating the rolling process with a higher speed, such as a finishing mill.

Temperature field analysis and its application in hot continuous rolling of Inconel 718 superalloy

A coupled thermo-mechanical model containing metal flow and temperature field for calculating temperature variation has been developed on fourteen-pass hot continuous rolling of round rod for Inconel 718 alloy using 3D elastic-plastic finite element method （FEM）. The temperature of characteristic analysis points in the intermediate cross-section of the workpiece has been simulated at initial temperature ranging from 960 to 1000 ℃ and initial velocity in range of 0.15-0.55 m·s^-1. Based on finite element analysis and microstructural observation in cylindrical hot compression experiments, the appropriate hot continuous rolling technologies have been designed for rod products with different diameters. For a real rolling practice, the simulated surface temperature was examined and is in good agreement with the measured one.

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.

Deformation Stability of GH4033 Superalloy in the Hot Continuous Rolling Process Based on Dynamic Material Model and Finite Element Model

The flow stress behavior of GH4033 superalloy was determined by the hot compression tests at the temperatures of 1223-1473 K and the total strains of 0.6 with the strain rates of 0.001-30.0 s^(-1) by using cylindrical samples.The processing maps based on the dynamic material model(DMM)combined with the corresponding microstructure observations indicate the reasonable processing domain locating at the strain rates of 0.1-1.0 s^(-1) and the deformation temperature of 1273-1423 K.Meanwhile,the numerical simulation based on finite element model(FEM)described the variation of the effective strain,effective strain rate and the temperature for the core node,and unveiled the influence of the hot rolling parameters considering the initial temperature(T_(0))range of 1223-1473 K and the first-stand biting velocity(v_(0))range of 0.15-0.35 m·s^(-1).Furthermore,the deformation stability of GH4033 superalloy in the round rod hot continuous rolling(HCR)process is described and analyzed by coupling the three-dimensional(3-D)processing map,and the spatial trajectory lines were determined by the numerically simulated temperatures,the strains and the strain rates.Finally,the results show that the hot deformation stability of GH4033 can be achieved by the rolling process parameters located at T_(0)=1423 K and v_(0)=0.25 m·s^(-1).Additionally,the practical HCR processes as T_(0)=1423 K and v_(0)=0.15,0.25,0.35 m·s^(-1) were operated to verify the influence of the hot rolling parameters on the hot deformation stability by the microstructure observation of the final products.

Numerical simulation on microstructural evolution during multipass hot-rolling of aluminum alloys

Numerical simulation on microstructural evolution during multipass hot rolling of aluminum alloys was performed by using DEFORM TM software and incorporating Zener Hollomon parameter Z . The distributions of equivalent stress, equivalent strain, equivalent strain rate and temperature, as well as the distribution of recrystallization fraction through the thickness of deformed specimen during multipass hot rolling of 5182 aluminum alloy, were all calculated. The results agree well with the metallographic examination of the deformed specimen on Gleeble 1500. [

Slab Storage Calculation Method for Continuous Casting-Hot Rolling

Based on load-oriented manufacturing control theory,different combining modes and slab storage calculation method for continuous casting and hot rolling were discussed.The buffer capacity index of continuous casting-rolling was introduced,and the reasonable slab storage under different combining modes was calculated with buffer capacity index of 120.00 hfor CCR,79.20 hfor HCR,19.68 hfor DHCR and 3.84 hfor DR.Thin slab is 1.20 h,and the strip is zero.Theory gist was provided for steel enterprise to decrease storage.

Computer Simulating Calculation on the Microstructure Evolutions during Hot Strip Rolling of C-Mn Steels

The program to predict the microstructure evolutions during hot strip rolling of C-M n steels has been developed in this paper, BV using this program, the microstructure changes with the processing parameters were analysed in detail. showing not only a good agreement of prediction with the measured values, but also entirely possibility to optimize hot strip rolling precess by computer simulation

Comparison of evolution laws of stress and strain fields in hot rolling of titanium alloy large rings with different sizes

For hot rolling of titanium alloy large rings,evolution laws of stress and strain fields in rings with various sizes were explored and compared based on a reliable coupled thermo-mechanical three-dimensional （3D） finite element （FE） model.The results show that for forming processes of different rings,as γ^-（the equivalent distribution ratio of feed amount per revolution of a process） decreases,the final peak Mises stress may transfer from the biting point at the driver roll side to that at the idle roll side,and the final peak equivalent plastic strain may transfer from the outside surface to the inside surface;as L^- （the equivalent deformation zone length of a process） increases,the final peak Mises stress may appear in the middle layer.The final positions of peak Mises stress and equivalent plastic strain are the combined effects of the above two aspects.In the deformation zone of a deformed ring,the surface layers are in the 3D compressive stress state,while the middle layer is in the 1D compressive and 2D tensile stress state or 2D compressive and 1D tensile stress state;the whole ring is in the 1D compressive and 2D tensile strain state.

Head Curvature of Pure Titanium Sheet Influenced by Process Parameters and Controlling in Hot Rolling Process

We investigated the influences of process parameters on the head curvature of pure titanium sheet in hot rolling process and proposed the controlling means. First, the thermal simulation experiments for pure titanium TA1 were carried out to investigate the hot deformation behaviors of pure titanium in the temperature range of 700-800 ℃ with strain rate range of 1-20 S-1, and the processing map was established to determine optimized deformation parameters. Then, the finite element model has been constructed and used to analyze the effect of process parameters on the direction and severity of head curvature of pure titanium sheet. The process parameters considered in the present study include workpiece temperature, work roll diameter, pass reduction, oxide scale thickness of workpiece surface, and interface friction coefficient. The simulation results show that the workpiece temperature and the interface friction coefficient are the two main factors. The proposed controlling means was carried out on a hot rolling production line and solved the head curvature problem effectively. The rolling practices indicate that the rolling yield is improved greatly.

Study on Influence of Initial Rolling Temperature for Rolling Process Based on Numerical Simulation

Wire rolling is a typical large deformation process and its principle is very complex,which includes material non- linearity,geometry non-linearity and boundary non-linearity.It is difficult to obtain theory analytical results by trying to roll or physical experiment because they will induce many problems such as high cost,waste time and venture.With the rapid advance- ment of computing technology and numerical method,the finite element method is regarded as the best one,which can account for the large plastic deformation,thermo-mechanical coupling and complex boundary conditions of the rollers and the workpiece inter- actions in the rolling process.Under the different initial rolling temperature,the two-pass hot continuous rolling process of high- speed wire has been simulated accurately for the pre-finishing rolling section.The metal fluxion law and the deformation field have been obtained.Strain,temperature,rolling force and torque also have been simulated and discussed.The results of simulation are useful for practical manufacture and the optimization of process-parameters.

Generalized Mathematical Model for Hot Rolling Process of Plate

A generalized mathematical model is developed to predict the changes of temperature, rolling pressure, strain,strain rate, and austenite grain size for plate hot rolling and cooling processes. The model is established mainly by incorporating analytical and numerical method for differential equations under complicated boundary conditions. An industrial rolling and cooling process of plate is simulated by the model, in which the thickness of steel Q235B plate is rolled from initial 200 mm to final 12 mm by 13-passes in a two-high mill. The calculated results are in good agreement with measured data. Different from FEM simulation, the model takes very short time in calculation and makes the influence of rolling passes on precision to be very slight.

PHYSICAL SIMULATION OF CONTINUOUS ROLL CASTING PROCESS

A series of simulating experimental studies on the rheological behavior and its influential factors of aluminum alloy in continuous roll-casting process have been explored in this paper with a Gleeble-1500 Thermal-Mechanical Simulation Tester and a set of special clamp system. Relevant rheological rules in the process of coupling transient solidification and continuous deformation of roll-casting conditions are obtained. Experimental results indicate that four different characteristic stages exist in the whole rheological process, and relative constitutive models suitable for the given conditions of continuous roll casting process have been established through multivariable linear regression analysis of the experimental data.

Full-length model with multi-point settings for finishing rolling

Thickness,width,temperature,and profile are considered as control targets in process control of hot strip finishing rolling. The pre-calculated settings of the model information include rolling force,cooling water flow between stands,bending force,and roll shifting position. Without changing the load distribution,the interaction among thread speed,rolling force,rolling power,and cooling water flow between stands is comprehensively considered based on the quantifiable relationship among speed,force,and temperature. This paper proposes a full-length multi-point-setting model that uses the settings of strip head to combine the rolling speed diagram with the target finishing mill delivery temperature( FDT) to achieve the calculation of the control parameters along full length of strip. Traditional models cannot effectively predict rolling force of strip body or the maximum and minimum temperatures of FDT. It is also difficult for traditional models to suppress fluctuations in shape accuracy of full-length strip or improve the shape accuracy of the product. Calculation results show that the proposed full-length multi-point-setting model can provide the control parameters for temperature and rolling-force over full length of strip,predict the risk of rolling exceeding the equipment capability,and improve the shape accuracy and rolling stability of hot-rolled products.

Numerical simulation of continuous roll-casting process of aluminum alloy

In order to improve the strip quality of continuous roll-casting process (CRP) of aluminum alloy, the investigations of the flow behavior within the metal pool, the heat transfer condition between roll and strip, the pouring temperature of molten alloy, the roll-casting speed and the control of the position of solidification final point are important. The finite volume method was applied to the analysis of the continuous roll-casting process. A two-dimensional incompressible non-Newtonian fluid flow with heat transfer was considered, which was described by the continuity equation, the Navier-Stokes equation and the energy equation. With this mathematical model, the flow patterns, temperature fields and solid fraction distributions in the metal pool between two rolls were simulated. From the calculated results, the effects of technical parameters to the position of solidification final point are obtained. The simulated results show that the roll-casting speed and pouring temperature have an enormous effect on the temperature distribution and the position of solidification final point.

Numerical simulation on recrystallization behavior and microstructure evolution during hot continuous rolling process of 38CrMoAl steel rod

The control of microstructure during hot rolling process of steel is of great importance and will affect the properties of the steel products.According to the production line,a three-dimensional multi-field coupled finite element model of 24-pass continuous hot rolling process of 38CrMoAl steel rod is established using the finite element software MSC.Marc.Based on the recrystallization kinetics model and the grain growth model,a subroutine written in Fortran is introduced to calculate the recrystallization behavior and microstructure evolution of 38CrMoAl steel during the entire rolling process.The distribution and evolution of variables such as strain,temperature and recrystallization fractions during the rolling process are analyzed.The temperature variations and grain sizes at both the center and surface of the tested steel are compared with the experimental results.And it is found that the simulation results are in good agreement with the experimental ones,confirming the reliability of the established model.