Control Method for Steel Strip Roughness in Two-stand Temper Mill Rolling

How to control surface roughness of steel strip in a narrow range for a long time has become an important question because surface roughness would significantly influence the appearance of the products. However, there are few effective solutions to solve the problem currently. In this paper, considering both asperities of work roll pressing in and squeezing the steel strip, two asperity contact models including squeezing model and pressing in model in a two-stand temper mill rolling are established by using finite element method（FEM）. The simulation investigates the influences of multiple process parameters, such as work roll surface roughness, roll radius and roll force on the surface roughness of steel strip. The simulation results indicate that work rolls surface roughness and roll force play important roles in the products; furthermore, the effect of roll force in the first stand is opposite to the second. According to the analysis, a control method for steel strip surface roughness in a narrow range for a long time is proposed, which applies higher work roll roughness in the first stand and lower roll roughness in the second to make the steel strip roughness in a required narrow range. In the later stage of the production, decreasing the roll force in the first stand and increasing the roll force in the second stand guarantee the steel strip roughness relatively stable in a long time. The following experimental measurements on the surface topography and roughness of the steel strips during the whole process are also conducted. The results validate the simulation conclusions and prove the effect of the control method. The application of the proposed method in the steel strip production shows excellent performance including long service life of work roll and high finished product rate.

Experimental Study on Surface Deterioration of Hot Rolling Mill Rolls under Near Service Conditions

With specially designed hot rolling test equipment,the surface deterioration process of hot rolling mill rolls can be simulated and representative samples were obtained.Thus a series of micro-analyses can be done onto the sample's worn surface,including wear loss,worn surface morphology,wear mode,oxidation and other influences from environment conditions.A leading study has been done with a high chromium cast iron to show the rolling test conditions and the methodologies of follow-up investigations for all the above-mentioned micro-analyses.Primary results have shown that high chromium iron roll may undergo complex degrading mechanism,and most of them can be investigated with the help of this research method-

STRESS ANALYSIS OF ROLL RING FOR HIGH SPEED WIRE ROLLING MILLS

This paper introduces a new method for fixing type of the tungsten carbide roll ring for high speed wire rolling mills, and analyses the stresses of the roll ring. The lifetime of roll pass is twice longer that of the old one.

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.

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.

Roll Shape Setting Technology of Hot Galvanizing and Planishing Mill

A roll shape setting model was built for the hot galvanizing and planishing mill. The uniform transversal distributions of the front tension in the exit and the unit pressure were considered as the objective function. At the same time, the quality of the products, the stability of zinc layer, and the homogeneity of spangles were of considerable significance in the planishing process. The model was applied to the roll shape setting of the 1800 cold rolling 3# CGL hot galvanizing and planishing mill of Baosteel Co Ltd. After being planished, the flatness of a strip that was less than 6 I was more than 97%, and the flatness of others were less than 10 I; the pass percentage of the zinc lay- ers reached 100%.

Backup roll contour of a SmartCrown tandem cold rolling mill

SmartCrown was a new system developed by VAI for improving the strip profile and flatness control first applied in 1700 mm tandem cold rolling mills at Wuhan Iron ＆ Steel （Group） Corporation （WISCO）. After tracing and testing, the application of the conventional crown backup roll matching the SmartCrown work roll of the production mill led to heavy and nonuniform wear, and the edge spalling of the backup roll often occurred. A 3-dimension finite element model of roll stacks was established, which was used to analyze the above-mentioned problems, and it was found that the main reason was the highly nonuniform contact pressure distribution between the work roll and the backup roll. A new FSR （flexible shape backup roll） was developed and applied in 1700 mm tandem cold rolling mills. A lot of good actual effects of FSR, such as evident improvement in profile and flatness of strips, non-occurring edge spalling, wear uniform, and remarkable decrease in roll consumption were validated by long-term industrial applications.

Recycle of valuable products from oily cold rolling mill sludge

Oily cold rolling mill （CRM） sludge contains lots of iron and alloying elements along with plenty of hazardous organic components, which makes it as an attractive secondary source and an environmental contaminant at the same time. The compound methods of ＂vacuum distillation ＋ oxidizing roasting＂ and ＂vacuum distillation ＋ hydrogen reduction＂ were employed for the recycle of oily cold rolling mill sludge. First, the sludge was dynamically vacuum distilled in a rotating furnace at 50 r/rain and 600℃ for 3 h, which removed almost hazardous organic components, obtaining 89.2wt% ferrous resultant. Then, high purity ferric oxide powders （99.2wt%） and reduced iron powders （98.9wt%） were obtained when the distillation residues were oxidized and reduced, respectively. The distillation oil can be used for fuel or chemical feedstock, and the distillation gases can be collected and reused as a fuel.

Modeling,Simulation and Experiment of Electro-hydraulic Screw Down Servo System of Seamless Tube Rolling Mill

Electro-hydraulic screw down servo system（HSDS） is widely used in seamless tube rolling mill in western companies.But in Chinese companies,mechanical screw down system（MSDS） is popularly equipped and has a serious disadvantage that the roller would often be locked when it is overloaded.For the purpose of designing the first set of domestic twin-roller,four-cylinder and six-framework electro-hydraulic HSDS of seamless tube rolling mill,an experiment system that can simulate the process of seamless tube rolling is constructed.A digital simulation model of the experiment system is built with AMESim software and validated by comparing the simulation results with experiment results.The sudden load response of the screw piston position is studied with the built model and the experiment system.To improve the HSDS＇s positioning accuracy with large load,a hybrid control scheme of combining load disturbance feedforward compensation（LDFC） method based on servo valve＇s pressure-stroke feature and anti-saturation integral control（ASIC） is proposed.Both results of simulation and experiment indicate that the transient response time of the single-roller HSDS with the proposed scheme decreases from 0.65 s to less than 0.2 s without static error.To improve the system dynamic stiffness and production qualified rate,a flow rate feedforward compensation（FFC） control strategy based on oil compressibility to dynamic position error is proposed.This FFC strategy is validated with experiments in which the transient error caused by sudden load is reduced to less than 25% of that without FFC.By extending the simulation model to HSDS of a twin-roller,four-cylinder rolling mill,analyzing the mill deformation,and applying the LDFC,ASIC and FFC to the HSDS,the dynamic performance and positioning accuracy of compensated multi-roller HSDS at biting moment are predicted.The research results provide a theoretical and experimental basis for the design of HSDS of seamless steel tube rolling mill.

Improvement on strip flatness of cold temper mills by modifying roll contour shape

A study on roll gap profile (strip profile) control was accomplished in a1700 mm single-stand temper mill. Some critical problems such as the deviation of work roll contourcaused by grinding and wear, the effectiveness of work roll bending were discussed. Using a finiteelement model, the effects of roll contours (ground and wear) on strip profile were investigated.The roll bending effect on strip thickness was also analyzed. It is pointed out that there are somespecial features of flatness control in the temper mill: during temper rolling, roll deformation isslight due to small rolling load, and the loaded roll gap profile mainly depends on work rollcontour, while the backup roll has a little effect on gap crown; the effect of bending force ongauge can not be ignored due to the coupling between flatness control and gauge control. A new rollcontour arrangement adaptable to the mill was presented and has been put into practical production.The application of the new set of rolls showed some good results: larger crown control range of workroll bender, higher rolling stability, better strip profile and flatness quality.

New technology for recycling materials from oily cold rolling mill sludge

Oily cold rolling mill （CRM） sludge is one of metallurgical industry solid wastes. The recycle of these wastes can not only protect the environment but also permit their reutilization. In this research, a new process of ＂hydrometallurgical treatment ＋ hydrothermal synthesis＂ was investigated for the combined recovery of iron and organic materials from oily CRM sludge. Hydrometallurgical treatment, mainly including acid leaching, centrifugal separation, neutralization reaction, oxidizing, and preparation of hydrothermal reaction precursor, was first utilized for processing the sludge. Then, micaceous iron oxide （MIO） pigment powders were prepared through hydrothermal reaction of the obtained precursor in alkaline media. The separated organic materials can be used for fuel or chemical feedstock. The quality of the prepared MIO pigments is in accordance with the standards of MIO pigments for paints （ISO 10601-2007）. This clean, effective, and economical technology offers a new way to recycle oily CRM sludge.

NUMERICAL SIMULATION FOR SHAPE OF COLD ROLLING ALUMINUM STRIP ON 4-HIGH MILL WITH ROLL SHIFTED

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Strontium ferrite powders prepared from oily cold rolling mill sludge by solid-state reaction method

Oily cold rolling mill （CRM） sludge is one of the pollutants emitted by iron and steel plants. Recycling oily CRM sludge can not only reduce pollution but also bring social and environmental benefits. In this study, using oily CRM sludge as sources of iron oxide, the strontium ferrite powders were synthesized in multiple steps including vacuum distillation, magnetic separation, oxidizing roasting, and solidstate reaction. The optimal technological conditions of vacuum distillation and oxidizing roasting were studied carefully. To consider the effects of Fe203/ SrCO3 tool ratio, calcination temperature, milling time and calcination time on magnetic properties of prepared strontium ferrite powders, the orthogonal experimental method was adopted. The maximum saturation magneti- zation （62.6 mA-m2.g-1） of the synthesized strontium ferrite powders was achieved at the Fe203/SrCO3 mol ratio of 6, 5 h milling time, 1250 ~C calcination temperature, and 1 h calcination time. Strontium ferrite powders syn- thesis method not only provides a cheap, high quality raw material for the production of strontium ferrite powders, but also effectively prevents the environmental pollution.

Analysis of rolls deflection of Sendzimir mill by 3D FEM

The deflection of rolls of Sendzimir mill with double AS-U-Roll was simulated by finite element method(FEM). The influences of rolling pressure, strip width and rolls-assignment on rolls deflection were analyzed. The results show that the work roll deflection increases with the increase of rolling pressure and the reduction of work roll radius, but the rigid displacement of work roll slightly changes; the work roll end might appear negative displacement for the narrow strip width and high rolling pressure that might cause the contact of work rolls. The research results are significant for guiding production and theoretical analysis of the rolls system of Sendzimir mill.

Synthesis and properties of SrFe_(12)O_(19) obtained by solid waste recycling of oily cold rolling mill sludge

The aim of this study was to develop a new approach for the preparation of environmentally friendly, high-value products from oily cold rolling mill(CRM) sludge. Utilizing oily CRM sludge as a source of iron, strontium hexaferrite(SrFe_(12)O_(19)) powders were prepared by multi-step processes involving acid leaching, chemical conversion treatment, and synthesis by a citrate precursor. The influences of citric acid dosage and the pH of the sol system on the formation, crystallite size, and magnetic properties of the obtained SrFe_(12)O_(19) powders were investigated. High saturation magnetization(74.8 mA·m^2·g^(–1)) and intrinsic coercivities(614.46 mT) were achieved for pH 7.0 of the sol system, for which the molar ratio of citric acid dosage to the total dosage of Fe^(3+) and Sr^(2+) was 1.5. This study presents a new approach to utilizing oily CRM sludge, and even refractory iron-containing solid waste.

Investigation for parametric vibration of rolling mill

The vibration unsteady condition of rolling mill caused by flexural vibration of strip has been investigated. The parametric flexural vibration equation of rolled strip has been established. The parametric flexural vibration stability of rolled strip has been studied and the regions of stability and unstability have been determined based on Floquet theory and perturbation method. The flexural vibration of strip is unstable when the frequency of variable tension is two times as the natural frequency of flexural vibration strip. The characteristic of current in a temp driving motor’s main loop has been studied and tested, it has been proved that there are 6 harmonic component and 12 harmonic component in main loop of driving motor electricity. The vertical vibration of working roller has been tested, the test result approves that the running unsteady is caused by parametric vibration. It attaches importance to the parametric vibration of rolling mill.

Investigation for Electromechanical Coupling Unstability of Rolling Mill

The unsteady condition of rolling Mill vibration that was caused by flexural vibration of strip was investigated. The parametric flexural vibration equation of rolled strip was established. The parametric flexural vibration stability of rolled strip was studied and region of stability and unstability was determined based on Floquet theory and perturbation method. The flexural-vibration of strip was unstable if the frequency of variable tension was twice as the natural frequency of flexural-vibration strip. The characteristics of electric current in a temp driving motor’s main loop was studied and tested, and approved that there were 6 humorous current ponderance and 12 humorous current ponderance in main circuit of driving motor. Vertical vibration of working roller was tested, the test approved that there were running unsteady caused by parametric vibration. It attached importance to the parametric vibration of rolling mill.

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.

Modeling for driving systems of four-high rolling mill

A modeling method for driving systems of four high rolling mill was put forward in order to analyze the origin of rolling mill’s chatter that brings about light and shade streaks on the surface of steel strip from aspect of electromechanical coupling. The process and steps of modeling method was introduced by means of an example. The correctness of the model and the feasibility of the modeling method were verified in simulation experiment.

Finite element analysis of shape control for continuous hot rolling mills of super wide strip steel

The efficacy of shape control is the core of this technology and the main basis of automatic shape control system model designing. This passage constructs the three-dimensional elastic deformation model of CVCplus roll system in 2250 mm hot rolling mill. Comparing and analyzing different influence of working factors on control characteristic, the shape control characteristic of CVCplus roll system in its whole work time is studied, and the cause is analyzed and the difference of the roll gap curve and crown adjustable area in early and latter work time is compared. The outcome has crucial meaning in both theory and production.