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.

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.

Multi-objective optimization of rolling schedule based on cost function for tandem cold mill

In terms of tandem cold mill productivity and product quality, a multi-objective optimization model of rolling schedule based on cost fimction was proposed to determine the stand reductions, inter-stand tensions and rolling speeds for a specified product. The proposed schedule optimization model consists of several single cost fi.mctions, which take rolling force, motor power, inter-stand tension and stand reduction into consideration. The cost function, which can evaluate how far the rolling parameters are from the ideal values, was minimized using the Nelder-Mead simplex method. The proposed rolling schedule optimization method has been applied successfully to the 5-stand tandem cold mill in Tangsteel, and the results from a case study show that the proposed method is superior to those based on empirical formulae.

Control of Surface Thermal Scratch of Strip in Tandem Cold Rolling

The thermal scratch seriously affects the surface quality of the cold rolled stainless steel strip. Some researchers have carried out qualitative and theoretical studies in this field. However, there is currently a lack of research on effective forecast and control of thermal scratch defects in practical production, especially in tandem cold rolling. In order to establish precise mathematical model of oil film thickness in deformation zone, the lubrication in cold rolling process of SUS410L stainless steel strip is studied, and major factors affecting oil film thickness are also analyzed. According to the principle of statistics, mathematical model of critical oil film thickness in deformation zone for thermal scratch is built, with fitting and regression analytical method, and then based on temperature comparison method, the criterion for deciding thermal scratch defects is put forward. Storing and calling data through SQL Server 2010, a software on thermal scratch defects control is developed through Microsoft Visual Studio 2008 by MFC technique for stainless steel in tandem cold rolling, and then it is put into practical production. Statistics indicate that the hit rate of thermal scratch is as high as 92.38%, and the occurrence rate of thermal scratch is decreased by 89.13%. Owing to the application of the software, the rolling speed is increased by approximately 9.3%. The software developed provides an effective solution to the problem of thermal scratch defects in tandem cold rolling, and helps to promote products surface quality of stainless steel strips in practical production.

Strain rate and cold rolling dependence of tensile strength and ductility in high nitrogen nickel-free austenitic stainless steel

The tensile strength and ductility of a high nitrogen nickel-free austenitic stainless steel with solution and cold rolling treatment were investigated by performing tensile tests at different strain rates and at room temperature. The tensile tests demonstrated that this steel exhibits a significant strain rate and cold rolling dependence of the tensile strength and ductility.With the increase of the strain rate from 10^-4s^-1to 1 s^-1, the yield strength and ultimate tensile strength increase and the uniform elongation and total elongation decrease. The analysis of the double logarithmic stress–strain curves showed that this steel exhibits a two-stage strain hardening behavior, which can be well examined and analyzed by using the Ludwigson equation. The strain hardening exponents at low and high strain regions（n2and n1） and the transition strain（εL） decrease with increasing strain rate and the increase of cold rolling RA. Based on the analysis results of the stress–strain curves, the transmission electron microscopy characterization of the microstructure and the scanning electron microscopy observation of the deformation surfaces, the significant strain rate and cold rolling dependence of the strength and ductility of this steel were discussed and connected with the variation in the work hardening and dislocation activity with strain rate and cold rolling.

Allowable variation of cold-rolled strip transverse profiles in high tension

The formation mechanism of the cold-rolled strip shape with high tension was studied. An advanced method to calculate the allowable variation of strip transverse profiles was established by the strip buckling criterion, which can be more properly used in cold rolling. With this method, the aim allowable variation of the product strip transverse profile and the required transverse profile range of incoming strips can be reached. Besides, this method has been successfully applied in a domestic tandem cold mill, and the transverse profile range of incoming strips suggested with this method is more practicable and complete. Consequently, the good performance is acquired.

Study on microstructure and properties of cold-rolled high strength steel for enameling

With its superior comprehensive properties, cold-rolled enameling steel is widely applied in many fields. However, its low yield stress greatly limits its application. This study aims to improve the yield stress of cold-rolled enameling steel under the premise of meeting formability and enameling properties by strengthening the ferrite matrix via solid strengthening of Mn. The grain size of ferrite before and after enameling,mechanical properties of annealed steel, and precipitation behavior of second-phase precipitates are obtained through studying the microstructure and properties of enameling steel at different stages. The microstructure of the steel investigated at room temperature is found to contain equiaxial ferrite and bunchy cementite particles;the ferrite grains have grown to some extent after enameling. The fine dispersed TiC particles and cementite particles contained in the annealed steel are the main factors improving the hydrogen storage capability. Finally, the result of a falling-ball impact test shows that the steel has achieved excellent adherence.

Research on the design of cold rolled ultra high strength sheet steel

This study researches cold rolled ultra high strength martensitic steel processed by water quenching. It is found that both the quenching and overageing temperatures greatly influence the mechanical properties of martensitic steel. A tensile strength of 1500 MPa can be obtained from 0.2% C-1.8% Mn steel by soaking at 840℃,quenching at 700℃ and overageing at 200℃ for several minutes. The continuous cooling transformation （CCT） diagram reveals that full martensite can be obtained at a cooling rate of 100℃/s or higher; and at a cooling rate of 3 - 10℃/s,austenite barely decomposes at 700℃. For steel with 0.2% carbon and less manganese, austenite decomposition occurs before it is cooled to 700℃ at a cooling rate of 3 - 10℃/s, which leads to lower tensile strength. It is possible to reduce the manganese content of the 1500 MPa martensitic steel by increasing the quenching temperature. To increase the quenching temperature,the control of flatness during water quenching becomes a major concern.

Effect of deformation twinning on the evolution of texture in TWIP steels during cold-rolling

Texture evolution of high-manganese twining-induced plasticity (TWIP) steels (Fe-16Mn-0.6C) during cold-rolling is studied by means of quantitative orientation distribution function (ODF)analysis.Thickness reductions of the specimens during cold-rolling are 10%,20%,30%,50% and 65%,respectively.Evolution of texture is of the Brass type,which is typical for low-stacking fault energy (SFE) materials.The contribution of deformation twinning to the development of texture is clearly illustrated by the monotonic increase of the twinned Cu component.In the present study,the deformation twinning was identified as significantly contributing to deformation up to the maximum reduction applied.These results are useful for the prediction and control of the texture in TWIP steels.

Numerical simulation of roll temperature field and analysis of influence factor during the single-stand reversing cold rolling process

Accurate calculation results of roll temperature are the key factors in rolling cooling and lubricating technology during the single-stand reversing cold rolling process. By combining the high-strength steel rolling experiments ,the numerical simulation of roll temperature, and the influence factors in reversing cold rolling were studied. The research results correspond with those of rolling experiments and show that the research method could provide effective instruction for roll cooling and emulsion flow rate control during the on-site rolling process.

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.

Modeling and Analysis of Interstand Tension Control in 6-high Tandem Cold Rolling Mill

The interstand tension control is one of the most important ways to meet tight tolerances for strip product quality during tandem cold rolling process. Using coordinate analysis and parabolic approximation for the mass flow balance principle, the strip velocities eliminating the use of forward slips and backward slips were calculated. In order to reduce the effect of roll eccentricity on the tension measurement, a filter based on bilinear transformation was de- signed. Applying a first-order Taylor series approximation, the transfer function matrix model of interstand tension stress was derived. The actual measurements on-site and the final calculation results showed that the established model had high calculation accuracy and was beneficial for interstand tension control of random cold rolling process.

Influence of friction-lubrication characteristics varying with rolling speed on instability of chatter and slip in cold tandem rolling process

In the high-speed cold tandem rolling process of thin plate,chatter or slip instability gives rise to the deterioration of equipment and product quality.Macroscopic instability behavior is closely related to interfacial friction-lubrication con-dition which is generally characterized by the friction coefficient.However,with higher and higher speed requirements,the commonly used model of friction coefficient is no longer applicable and accurate.A novel approach is suggested to calculate the speed-dependent friction coefficient,in which the viscosity-pressure-temperature effects of the lubricant,surface roughness states of work rolls and rolled piece are comprehensively involved and the mixed flm lubrication theory is applied.Subsequently,the influences of friction coefficient on the instability of slip and chatter are investigated for a five-stand cold tandem rolling mill.On one side,the critical friction coefficient for each stand is determined by calculating the corresponding slip factor;on the other hand,the friction coefficient varying with rolling speed is combined with the model of theoretical critical rolling speed presented under constant friction coefficient,so that the speed threshold is determined.Furthermore,the stable and unstable regions corresponding to the rear three stands are individually discussed,and the technical strategies are proposed to suppress both slip and chatter frequently occurring in the actual rolling process.

Effect of thermomechanical processing on microstructure and mechanical properties of CoCrFeNiMn high entropy alloy

The CoCrFeNiMn high entropy alloy was produced by homogenization, cold rolling and recrystallization. The effects of thermomechanical processing on microstructures and tensile properties at different temperatures were investigated using X-ray diffractometry（XRD）, optical microscopy（OM）, scanning electron microscopy（SEM） and multi-functional testing machine. The results show that dendritic structures in cast alloy evolve into equiaxed grains after being recrystallized, with single face-centered cubic（FCC） phase detected. The most refined alloys, stemming from the highest rolling ratio（40%）, exhibit the highest strength due to the grain boundary strengthening, while the variation of elongation with temperature shows a concave feature. For the coarse-grained alloys, both the ductility and work hardening ability decrease monotonically with increasing temperature. Serrated flow observed at intermediate temperatures is attributed to the effective pinning of dislocations, which manifests the occurrence of dynamic strain hardening and results in the deterioration in ductility. Besides, dimples on the fracture surfaces indicate the typical ductile rupture mode.

SENSITIVITY ANALYSIS FOR ROLLING PROCESS BASED ON SUPPORT VECTOR MACHINE

A method for the calculation of the sensitivity factors of the rollingprocess has been obtained by differentiating the roll force model based on support vector machine.It can eliminate the algebraic loop of the analytical model of the rolling process. The simulationsin the first stand of five stand cold tandem rolling mill indicate that the calculation forsensitivities by this proposed method can obtain a good accuracy, and an appropriate adjustment onthe control variables determined directly by the sensitivity has an excellent compensation accuracy.Moreover, the roll gap has larger effect on the exit thickness than both front tension and backtension, and it is more efficient to select the roll gap as the control variable of the thicknesscontrol system in the first stand.

Dynamics-based optimization of rolling schedule aiming at dual goals of chatter suppression and speed increase for a 5-stand cold tandem rolling mill

In the process of cold tandem rolling,chatter instability leads to serious impacts on enhancing rolling speed,improving product quality,reducing production cost and realizing intellectualization.Chatter occurs with the rolling speed up to a certain threshold value,but the critical speed is determined by both product specifications and rolling schedules.A 5-stand cold tandem rolling mill whose first three stands and subsequent two stands,respectively,have four and six rolls was investigated by formulating its dynamic equations with the corresponding structure-process coupling.By applying the stability-based calculation model about the critical rolling speed in each stand,the system dynamic responses around the critical rolling speed were simulated,and the system eigenvalues which represent instability and characteristic frequencies were figured out.Thereafter,via combining the critical rolling speeds with the system dynamic behavior,a dynamics-based optimization model of rolling schedule for the 5-stand cold tandem system was proposed for the purposes of both the chatter suppression and rolling speed increase.In the optimization model,eight rolling technique parameters(four strip thicknesses and four tensions between the upstream and downstream stands)were taken as design variables,and the constraint conditions were set as no chatter instability in all five stands,and the optimization goal was to maximize the outlet speed of the final stand.The pattern search method was introduced to solve the optimization model.By applying such a dynamics-based optimization model for the 5-stand cold tandem rolling process,the chatter instability was suppressed effectively and the rolling efficiency was improved considerably;therefore,such an optimization model is expected to be valuable for intelligent manufacturing of rolling process.

Vibrations of tandem cold rolling mill: coupled excitation of rolling force and variable stiffness of fault-free back-up roll bearing

Vibration issues of a five-stand tandem cold rolling mill were found in the steel production practice,and the experimental observation and numerical analysis indicated that the vibrations were related to the back-up roll bearing.The results were validated by replacing the back-up roll bearing with the new bearing resulting in 30%decline in vibration amplitude.Models describing the four-row cylindrical roller bearing and the vertical system of the cold rolling mill including the bearing were established.Moreover,the mechanisms of periodic excitation and amplified vibrations of fault-free bearing were explained theoretically,along with the analysis of bifurcation behaviors of the motion states of the roller bearing and rolling mill system.It is found that the energy transmitted between vibrations with different frequencies if multiple excitation frequencies in the rolling mill system were close.

Investigation into microstructure of spray formed V4 cold working mould steel and its roiling and annealing

The material selected for this work was the spray formed Vanadis4 high alloy cold working mould steel （abbreviated to V4 steel）. Its microstructure, hot rolling process, and annealing treatment have been investigated. Observed from the optical and electron microscopes, the as-sprayed V4 steel had the finer microstructure of uniform and equiaxial grains ,while after hot rolling for densification and spheroidized annealing, the V4 steel obtained an excellent spheroidized structure that is favorable to subsequent quenching and tempering treatment. The spheroidized structure and level of annealed hardness of the V4 steel are almost the same as expensive imported powder metallurgy the V4 steel. It is difficult to produce V4 steel with the conventional ingot metallurgical technique, so the multi-step and high-cost powder metallurgy method is generally used at present. Compared to the powder metallurgy technique, using the spray forming technique to produce the V4 steel has obvious advantages and potential market competitiveness in reducing production costs, simplifying working process, and shortening the production cycle.

四工作辊轧机轧制304不锈钢板件截面塑性变形分析

针对四工作辊轧机轧制304不锈钢板件存在变形量大、尺寸不稳定的问题,利用Solidworks软件建立四工作辊轧制系统有限元模型,采用Deform软件对304不锈钢板件在不同轧辊直径、轧辊转速和轧辊压下量下进行轧制仿真,分析其对轧件截面高度和等效应力分布的影响,根据轧制仿真分析结果设计制造了四工作辊轧机,并对不同压下量下仿真和生产的轧件截面高度进行对比分析。结果表明,轧件截面塑性变形可分为相互作用Ⅰ区、过渡Ⅱ区和变形Ⅲ区,等效应力、等效应变和截面高度在Ⅰ区最大,在Ⅲ区最小且变化平稳,Ⅱ区值位于两者之间并呈U型分布。

高性能高精度铜合金带材六辊冷轧机组的研发与应用

针对高性能高精度铜带材生产的技术难点,首次开发了800 mm小辊径六辊可逆中精轧机组。介绍了机组的工艺设备组成、主要工艺技术参数配置和装机水平;重点阐述了开发的新技术:紧凑式弯辊小辊径六辊轧机、高精度自动厚度控制技术、高精度板形自动控制系统以及高效除油装置。机组投入使用后,产品质量得到有效提高,对于厚度为0.175 mm,宽度为620 mm的铜带,成品厚差不大于±1μm,板形均方差不大于0.55I。