Using commercial finite element (FE) analysis software DEFORM-3D, a rigid plastic thermomechanical finite element model was developed to investigate inhomogeneous plastic deformations during heavy plate hot rolling. A single pass rolling process, a longitudinal rolling process and a broadside-longitudinal rolling process were simulated by this 3D FE model. The simulated results of the broadside-longitudinal rolling process were in good agreement with the actual rolled one. Basing on the simulation results, formation laws of concave side shapes and convex end shapes were clarified. Evolutions of the uneven shapes in the longitudinal rolling process and the broadside-longitudinal rolling process were analysed in detail. The results obtained from the simulation results provided guidelines for further investigation on plate plan view pattern control.
A hydrodynamics method (HM) has been developed to predict the contact stresses in hot strip rolling. This method is based on that materials deformed in hot rolling present properties of viscous fluid. The contact stress formulas are derived from Navier–Stokes equation (N‐S equation) by using HM. The contact stresses predicted by these formulas agreed well with the experiment data, which verified the validity of these formulas. By comparisons of experiment data with the results predicted by the derived formulas, the Amontons–Coulomb friction model (ACM) and the Absolute constant friction model (AFM), it is found that formulas derived by HM can smooth the friction hill and has higher accuracy in predicting the neutral plane positon than the ACM and the AFM did. It is believed that the contact stress formulas derived by HM can be used to solve on line hot rolling problems.
From a new viewpoint to improve plate plan view pattern during hot rolling, a plate edging process was proposed to roll back only the plate width spread of conventional rolling in this paper. Using commercial finite element (FE) analysis software DEFORM-3D, a three-dimensional rigid plastic FE model for vertical-horizontal (V-H) hot rolling was developed on the basis of a 5 m wide and heavy plate mill. Three hundred and twenty kinds of different V-H rolling processes were simulated by the FE model. Basing on the simulation results, the formation laws of dog bone shape during the vertical rolling and the width spread behaviours during the horizontal rolling were clarified. A plate edging model predicting the plate edging efficiency was established with the aid of an artificial neural network. The plate edging efficiency predicted by this plate edging model agreed well with those predicted by the existing strip edging models when the slab width/thickness ratio was small, which confirmed the validity of the plate edging model. The plate edging model expanded its application scope into the wide and heavy plate hot rolling.
On the basis of Shagang Group's 5000 mm heavy plate mills, conventional rolling processes with different broadside rolling ratios were simulated by the three-dimensional rigid plastic thermomechanical finite element (FE) model developed in the author's previous work. By analysing the simulation results, it was found that the final plate plan view patterns after hot rolling processes were bound closely to the broadside rolling ratio and the finishing rolling ratio. Then, predictive models for plate end edge shapes and side edge shapes were formulated by nonlinear regressive analysis of the simulation results and modified by the lengths of the uneven shapes for higher accuracy. The validity of the prediction models was confirmed by comparing the predicted concavity and convexity lengths with those measured from industrial tests. The predicted plate edge shapes were in good agreement with those of the FE simulation. On the basis of the plate plan view pattern prediction models, methods to improve the plate plan view pattern are discussed.
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