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.

Towards Energy Efficient Shape Rolling:Roll Pass Optimal Design and Case Studies

Shape rolling is widely employed in the production of long workpieces with appropriate cross-section profiles for other industrial applications. In the development of shape rolling systems, roll pass design (RPD) plays an essential role on the quality control of products, service life of rolls, productivity of rolling systems, as well as energy consumption of rolling operations. This study attempts to establish a generic strategy based on hybrid modeling and an improved genetic algorithm, to support the optimizations of RPD and shape rolling operations at a systematic perspective. Objectives include improving the quality and efficiency of RPD, reducing energy consumption of shape rolling, as well as releasing the demands on costly trails and expert knowledge in RPD. Hybrid modeling based on cross-disciplinary knowledge is developed to overcome the limitations of isolated single-disciplinary models. And conventional genetic algorithm is improved for the implementation of optimal design. Targeting to integrate empirical data and published reliable solutions into optimizations, a parameters estimation method is proposed to transfer the initially misaligned models into a uniform pattern. A tool based on the Matlab platform is developed to demonstrate the optimal design operations, with case studies involved to validate the proposed methodology.

Forced transverse vibration of rolls for four-high rolling mill

In order to investigate the forced transverse vibration of rolls under distributed draught pressure and moment of bending roll force, the forced transverse vibration model of rolls for four-high rolling mill was established. The work roll and backup roll were considered as elastic continuous bodies that were joined by a Winkler elastic layer. According to Euler-Bemoulli beam theory, the forced transverse vibration of rolls was analyzed based on modal superposition method. The forced vibration equations were established when the draught pressure and moment of bending roll force were imposed on the rolls respectively. Numerical modeling was made on 2 030 mm cold tandem rolling mill of Baoshan Iron and Steel Company. Simulation results show that when the work roll is only subjected to different forms of draught pressures, the vibration curves of work roll and backup roll are quadratic curves with amplitudes of 0.3 mm and 45 μm, respectively. When only the moments of bending roll force are imposed on the work roll and backup roll, the vibration curves of work roll and backup roll are quadratic curves, and the amplitudes are 5.0 and 1.6 μm, respectively. The influence of moment of bending roll force on the vibration of work roll is related with the bending roll force.

INFLUENCES OF EDGING ROLL SHAPE ON THE PLASTIC STRAIN DISTRIBUTION OF SLAB DURING MULTI-PASS V-H ROLLING PROCESS

Multi-pass slab vertical-horizontal （V-H） rolling process with variable edging roll shape have been simulated with explicit dynamic finite element method and updating geometric method. The distributions of plastic strain contour in slab daring rolling process with different edging roll and under different rolling stage have been obtained. The results show that there exist two thin strain assembling zones in slab when the flat edging roll is used, and there just exist one strain assembling zone in slab when the edging roll with groove is used. And compared the deformation equality between flat edging roll and edging roll with groove, the lateris better than the former, which supplies the theory prove to the slab deformation distribution during V-H rolling process and is helpful for predicting the slab texture.

Effects of rolling parameters of snake hot rolling on strain distribution of aluminum alloy 7075

The realization way of snake rolling was introduced. Flow velocity, strain and stress distribution of 7075 aluminum alloy plate during snake rolling and symmetrical rolling were analyzed in Deform 3D. Effects of velocity ratio, offset distance between two rolls and pass reduction on the distribution of equivalent strain and shear strain were analyzed. The results show that flow velocity and equivalent strain on the lower layer of the plate are larger than those of the upper layer because of the larger velocity of the lower roll and the gap is increased with the increase of velocity ratio and pass reduction. The shear strain of roiling direction in the center point is almost zero during symmetrical rolling, while it is much larger during snake rolling because of the existence of rub zone. The shear strain is increased with the increase of velocity ratio, offset distance and pass reduction. This additional shear strain is beneficial to improve the in_homogeneous strain distribution.

NUMERICAL SIMULATION OF ROUND TO OVAL ROLLING PROCESS

Three dimensional thermal-mechanical coupled elasto-plastic FEM has been used for simulation of round to oval single pass rolling. The analysis was conducted using MARC/AUTOFORCE1. 2 code. The material is assumed to be elasto-plastic and it obey the Von Mises yield criterion and Prandtl- Reuss rule. Deformation of the workpiece is simulated in a step-by-step manner,updating the coordinates of material points and the property after each step, so that both nonsteady-state and stendy-state deformation can be simulated. The heat transfter between the workpiece, the rolls, and enviroment and the heat generation due to plastic work and friction force, are considered in the analys- is.Predicted the deformation shape of the workpiece, distributions of strains, stresses, strain rates and temperatures, roll-separating force and roll torque are presented.

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.

Effect of Load Distribution on Strip Crown in Hot Strip Rolling

In order to establish precision model, a software to calculate the strip crown of four-high hot rolling mill was developedby using affecting function method according to the strip crown calculation theory. The effect of work roll diameter,unit width rolling load, roll bending force, work roll crown, initial strip crown and reduction, etc, on load distributioneffect rate was simulated by using the software. The results show that the load distribution effect rate increaseswith the increase of strip width, work roll diameter, unit width rolling load, roll bending force, work roll crown,initial strip crown and reduction. Based on the simulation results, base value of load distribution effect rate andfitting coefficients of six power polynomial of load distribution effect rate modification coefficient were determinedconsidering all of the above parameters. A simplified mathematical model for calculating load distribution effect ratewas established.

Relationship between Hardness and Deformation during Cold Rolling Process of Complex Profles

The hardening on surface of complex profles such as thread and spline manufactured by cold rolling can efectively improve the mechanical properties and surface quality of rolled parts. The distribution of hardness in superfcial layer is closely related to the deformation by rolling. To establish the suitable correlation model for describing the relationship between strain and hardness during cold rolling forming process of complex profles is helpful to the optimization of rolling parameters and improvement of rolling process. In this study, a physical analog experiment refecting the uneven deformation during complex-profle rolling process has been extracted and designed, and then the large date set (more than 400 data points) of training samples refecting the local deformation characteristics of complexprofle rolling have been obtained. Several types of polynomials and power functions were adopted in regression analysis, and the regression correlation models of 45# steel were evaluated by the single-pass and multi-pass physical analog experiments and the complex-profle rolling experiment. The results indicated that the predicting accuracy of polynomial regression model is better in the strain range (i.e., ε < 1.2) of training samples, and the correlation relationship between strain and hardness out strain range (i.e., ε > 1.2) of training samples can be well described by power regression model;so the correlation relationship between strain and hardness during complex-profle rolling process of 45# steel can be characterized by a segmented function such as third-order polynomial in the range ε < 1.2 and power function with a ftting constant in the range ε > 1.2;and the predicting error of the regression model by segmented function is less than 10%.

卷积神经网络与有限元分析在棒材轧制孔型参数仿真中的应用

为了实现智能化轧制仿真过程,提出了将卷积神经网络(CNN)与有限元分析相结合的方法,利用机器代替人工选择出最佳的轧制仿真结果,并确定最优的孔型参数.首先,将CNN用于轧件道次分类,可发现“卷积神经网络+图像预处理”测试模型精度最高,为91.84%~96%;其次,使用5种评估方法对比轧制仿真结果与理想仿真结果后可得出,均方根误差和感知哈希对仿真结果更为敏感;最后,将孔型参数朝轧制仿真结果变优方向进行修正,对比仿真结果与修正前结果后发现,第2次修正更为理想.本研究中实现了CNN对棒材轧制道次分类,利用机器识别出更优的轧制仿真结果,并确定了更适合的孔型参数,在降低人力、物力消耗,以及实现仿真智能化等方面具有重要的理论意义和实际应用价值.

H型钢孔型设计及轧制规程研究

结合具体孔型设计实例,详细介绍了H型钢孔型设计应遵循的原则及方法,另外介绍了H型钢轧制规程的制定及力能参数的计算,通过力能计算来校核孔型设计的合理性。通过合理最优的孔型设计,保证开坯机和万能精轧机组之间压下变形均匀分配,各项负荷满足设备能力,实现型钢生产的稳定、高效运行,保证生产工艺的合理性。

滚仰式导引头斜置方案下的过顶奇异问题控制策略

在末制导阶段,由于制导目标位于弹体纵轴附近,滚仰式结构的导引头易出现奇异性问题而难以精确跟踪目标。针对上述问题,提出基于斜置方案的滚仰式导引头过顶奇异问题控制策略。在导引头稳定平台相对弹体斜置边界俯仰框架角的基础上,通过控制弹体的滚转运动,保证导引头光轴始终避开过顶奇异区域,实现目标位于弹体纵轴附近和斜置导引头初始光轴附近两个过顶奇异区域的稳定跟踪。研究结果表明:所提策略相比于增设第三轴的方法,导引头体积小、质量轻;相比于分区域变参数控制策略,解决了静止和减速控制时过顶奇异区域内导引头对视线角速度跟踪失效的问题;仿真对比结果验证了所提策略具有跟踪精确度高、有效抑制控制系统失稳、降低探测器失调角的特点。

鞍钢Φ110 mm圆钢孔型设计与轧制

鞍钢股份有限公司大型总厂连轧生产线设备升级后,采用“箱形-椭圆-圆-椭圆-圆”的孔型系统,完成了Φ110 mm圆钢孔型设计。轧制后,Φ110 mm圆钢平均成材率达到90.31%,外径在109.10~111.05 mm波动,平均椭圆度1.16 mm,满足生产要求。

基于改进EMD-Kurtogram法的滚动轴承早期故障诊断研究

实现滚动轴承早期故障准确诊断的关键是得到故障部位有效振动信息,但实际工程中所采集到的轴承振动信号常含有噪声、干扰成分,给有效信息的选择带来了困难。带通滤波是解决该问题的有效方法之一,但不合理的滤波器参数会降低诊断结果的准确性。为此,提出一种基于改进EMD-Kurtogram法的滚动轴承早期故障诊断方法。该方法首先对EMD方法处理后的采样信号进行重构,再根据快速谱峭度图得到带通滤波器所需要的最优参数,最后经过带通滤波及时频域分析得到故障频率。通过实验平台验证及相关算法的对比得出,所提方法得到的故障倍频信息更加充分、清晰,所含噪声干扰更少,证明了该方法的有效性和先进性。

B500BD13mm带肋钢筋四线切分轧制生产工艺开发

介绍了石横特钢棒材厂英标B500BD13mm热轧带肋钢筋四切分轧制生产工艺的设计。针对顶出口、切分刀粘铁、力学性能不稳定以及成品尺寸不符合标准问题,分别从提高轧机刚性、优化导卫结构、提高温度工艺控制精度和优化孔型、调整机架间张力的措施着手,实现了热轧带肋钢筋四切分的稳定轧制,最终形成工业化批量生产,年创效360万元,产品质量满足用户需求。

Binding property of Al/Mg/Al thin plates fabricated by one-pass hot rolling with different reduction ratios,temperatures and annealing treatments

In this study, Al-Mg-Al trilaminated thin plates were fabricated by one-pass hot rolling to improve the processing capacity and bonding strength of magne- sium alloy plates. The effects of processing parameters were investigated. The results show that the optimal bonding strength is up to 20 MPa with a reduction ratio of 40 % and rolling temperature of 400 ℃, superior than that in other one-pass rolling studies with regard to thin lami- nated plates. In addition, a favorable property is achieved with the annealing temperature of 250-300 ℃ or annealing time of 1.5 h. When the annealing temperature exceeds 300 ℃ or annealing time exceeds 1.5 h, respectively, the bonding strength of Al/Mg/Al plate decreases. The scan- ning electron microscopy （SEM） and energy-dispersive spectroscopy （EDS） analyses suggest that the appearance of thin diffusion layers between Al and Mg interfaces is helpful to improve the bonding strength, while the presence of thick diffusion layer would reduce the bonding strength greatly.

Modelling a Skin-Pass Rolling Process by Means of Data Mining Techniques and Finite Element Method

An experience is presented using the finite element method （FEM） and data mining （DM） techniques to develop models that can be used to optimieze the skin-pass rolling process based on its operating conditions. A FE model based on a real skin-pass process is built and validated. Based on this model, a group of FE models is simulated with different adjustment parameters and with different materials for the sheet; both variables are chosen from pre-set ranges, From all FE model simulations, a database is generated; this database is made up of the above mentioned adjustment parameters, sheet properties and the variables of the process arising from the simulation of the model. Various types of data mining algorithms are used to develop predictive models for each of the variables of the process.The best predictive models can be used to predict experimentally hard-to-measure variables （internal stresses, internal straine, etc.） which are useful in the optimal design of the process or to be applied in real time control systems of a skin-pass process in -plant.

Prediction of Velocity and Deformation Fields During Multipass Plate Hot Rolling by Novel Mixed Analytical-Numerical Method

An integrated mathematical model is proposed to predict the velocity field and strain distribution during multi-pass plate hot rolling. This model is a part of the mixed analytical-numerical method （ANM） aiming at predic- tion of deformation variables, temperature and microstructure evolution for plate hot rolling. First a velocity field with undetermined coefficients is developed according to the principle of volume constancy and characteristics of metal flow during rolling, and then it is solved by minimizing the total energy consumption rate. Meanwhile a thermal model coupling with the plastic deformation is exploited through series function solution to determine temperature distribution and calculate the flow stress. After that, strain rate field is calculated through geometric equations and strain field is derived by means of difference method. This model is employed in simulation of an industrial seven pass plate hot rolling process. The velocity field result and strain field result are in good agreement with that from FEM simulation. Furthermore, the rolling force and temperature agree well with the measured ones. The compari- sons verify the validity of the presented method. The calculation of temperature, strain and strain rate are helpful in predicting microstructure. Above all, the greatest advantage of the presented method is the high efficiency, it only takes 12 s to simulate a seven-pass schedule, so it is more efficient than other numerical methods such as FEM.

Effect of reduction in area per pass on strain distribution and microstructure during caliber rolling in twinning-induced plasticity steel

The effects of reduction in area(RA)per pass during caliber rolling on microstructure and strain distribution of twinninginduced plasticity steel have been investigated to find solutions to make a more homogeneous material along the radial direction for wire rod applications.The steel wires subjected to an average RA per pass of 2.5%(skin pass caliber rolling)and 10.0%(conventional caliber rolling)were analyzed.The skin pass caliber-rolled wire was characterized as a duplex fiber texture of major<111>and minor<100>.and the textures were almost same at/between center and surface area,which is totally different from those of conventional caliber rolling and wire drawing.The skin pass caliber rolling led to more homogeneous microstructure and mechanical properties along the radial direction in comparison with the conventional caliber rolling and wire drawing due to the more homogeneous Hall-Petch hardening,dislocation hardening,and texture behavior with area,resulting in higher formability.

中厚板轧制道次模型的研究

随着制造业的发展,中厚板生产对自动化和信息化技术的需求日益增长。本文针对中厚板生产过程的特点及要求,设计了一套二级轧制道次控制模型。该模型包括材料、物理、温度、再结晶、轧制策略、自适应6个子模型,可实现生产数据的实时处理,确保生产过程的高效运行和产品质量的稳定。通过在某中厚板生产线的应用,该系统表现出良好的稳定性和高效性,显著提高了生产效率与产品质量,降低了生产成本和资源消耗。