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.
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