Process modelling of flat rolling of steel

Jamal, Faisal; Rath, Sushant; Acherjee, Bappa

doi:10.1080/2374068x.2018.1526471

Cited by 9 publications

(9 citation statements)

References 7 publications

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“…Finite element methods (FEMs) have also been used in model rolling processes, owing to their versatility and capability to manage complex boundary conditions [8][9][10]. The main advantage of FEM with respect to slab analysis is the possibility of removing basic assumptions on stress distributions.…”

Section: Introductionmentioning

confidence: 99%

“…In the models presented in the works of [1][2][3][4][5][6][7][8][9][10][11], the influence of lubrication is not considered, but in the cold rolling mill process, a layer of lubricant is sprayed on the interface between the working rolls and the strip, to guarantee optimal superficial characteristics on high mechanical resistance metal strips. In fact, the use of lubricants reduces the friction and wear levels, ensures dimensional accuracy, and enhances the surface finish quality of the final product.…”

Section: Introductionmentioning

confidence: 99%

“…The novelty of the proposed model over the models presented in the works of [1][2][3][4][5][6][7][8][9][10][11] is that the influence of lubricants is considered. The novelty with respect to the presented previous models [12][13][14][15][16][17][18][19][20][21][22][23] is that the new model combines Orowan's inhomogeneous theory [24] for plastic deformation with the Reynolds equation in full film lubrication and the continuity conditions.…”

Section: Introductionmentioning

confidence: 99%

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A Numerical Procedure Based on Orowan’s Theory for Predicting the Behavior of the Cold Rolling Mill Process in Full Film Lubrication

2019

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In this paper, a numerical model for predicting the working parameters of the cold rolling mill process in full film lubrication is presented. The model is useful from an industrial point of view, because it can forecast the thickness reduction of the metal sheet and the pressure trend, so that the rolling mill process parameters can be regulated to obtain a specific output thickness. Experimental tests were performed, and results are compared to the theoretical ones resulting from the model. The novelty of the proposed model is that it combines Orowan’s theory for the plastic deformation analysis with the Reynolds equation in full film lubrication and the continuity conditions. The lubricant flow and viscosity are studied, taking in account their dependence on pressure and temperature. The proposed model describing the full film regime is also compared to another one, previously proposed by the authors, based on the well-known slab analysis and sharing with it the representation of the lubrication regime, the mathematical procedure, and the boundary conditions. The results show that the proposed model provides a better prediction of the working parameters with respect to the model based on the slab analysis.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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A Numerical Procedure Based on Orowan’s Theory for Predicting the Behavior of the Cold Rolling Mill Process in Full Film Lubrication

2019

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“…[6] In recent years, only few new contributions to this topic were published, for example, Kim et al, [7] Schmidtchen and Kawalla, [8] and Freshwater. [9,10] This approach's main benefit is the fast computation speed due to 1D differential equation formulation.The finite element theory is actively developed since the 1980s, for example, by Hwu and Lenard, [11] Jamal et al, [12] Jiang and Tieu, [13] Rout et al, [14] and Kainz et al [15] . It provides a general approach for complex problems in two or three dimensions and offers the high accuracy of the simulation results.…”

mentioning

confidence: 99%

“…The finite element theory is actively developed since the 1980s, for example, by Hwu and Lenard, [11] Jamal et al, [12] Jiang and Tieu, [13] Rout et al, [14] and Kainz et al [15] . It provides a general approach for complex problems in two or three dimensions and offers the high accuracy of the simulation results.…”

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confidence: 99%

Extension of the Freiberg Layer Model by Means of Elastic–Plastic Material Behavior

Weiner

Schmidtchen

Prahl

2021

steel research int.

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For development of new materials and improvement of material properties today simulation of the production processes is essential. The understanding of the processes' mechanics and thermodynamics give the ability of tuning the process toward property improvement and efficiency. Flat rolling is one of the main processes used for production of flat metal semiproducts such as sheets, strips, and plates. In simulation of flat rolling today, two main approaches are used. The first is the elementary theory of plasticity, also known as strip or slab method, which was the first theoretical approach to describe the conditions within the roll gap. The second one is the finite element method, which offers a general approach for complex problems.The elementary theory was established by von Kármán. [1] Well-known contributors are Ford et al., [2][3][4] Orowan, [5] and Alexander. [6] In recent years, only few new contributions to this topic were published, for example, Kim et al., [7] Schmidtchen and Kawalla, [8] and Freshwater. [9,10] This approach's main benefit is the fast computation speed due to 1D differential equation formulation.The finite element theory is actively developed since the 1980s, for example, by Hwu and Lenard, [11] Jamal et al., [12] Jiang and Tieu, [13] Rout et al., [14] and Kainz et al. [15] . It provides a general approach for complex problems in two or three dimensions and offers the high accuracy of the simulation results. The main disadvantage is the high computational effort in solving the equation systems, increasing rapidly with nonlinearity of the base equations and resolution of the problem space. Therefore, this method has grown along with the development of high-performance computer systems in the past decades. However, fast methods are needed for use in control systems or production scheduling. Some authors try to combine the slab method with partial finite element solutions to achieve a decrease in computation time, for example, Kim et al. [7] . Another approach was shown by Schmidtchen and Kawalla [8] in extending the elementary theory by dividing the strip element into a number of discrete layers. This turns the 1D resolution of the elementary theory into a 2D one. Nevertheless, this model only requires 1D differential equation solving, which can be done fast and easy with common numerical methods. Due to this 1D formulation, it can be easily coupled with microstructure and precipitation models. The model is currently used in industry for online-simulation and controlling of direct input steel plants, including microstructure and precipitation simulation. Due to the layering, it is suitable for inhomogeneity determined processes, such as block rolling and direct input, were conventional slab method fails. However, it is only able to describe the layers as in plastic or rigid state. This work has the aim to extend it by elastic-plastic material behavior. The influence of the elastic behavior should be investigated in comparison with the rigid-plastic layer model as well as to FEM simulatio...

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Extension of the Freiberg Layer Model by Means of Solidification for Roll Casting

2022

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Finite element method (FEM) simulations offer deep and detailed modeling of complex processes, but with a high effort of computation power and time. For the special purpose of flat rolling, a layer model is developed by Schmidtchen earlier based on the classic elementary theory of plasticity with the purpose to model inhomogeneous behavior with a significant lower effort at computation. In a previous work, this model was extended with elastic–plastic material behavior. Herein, the model is extended by a viscose zone at the entry for the modeling of roll casting. It is now possible to model the inhomogeneous solidification of a melt in the roll gap and proceed with elastic–plastic inhomogeneous flat rolling in the solid region. The results are compared with FEM simulations from the literature and found to fit well together. But, the current model offers more plausible stress curves in the solid region, because an elastic–plastic material model is applied, where common FEM simulations are only able to work with viscose material laws in the whole roll gap.

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Process modelling of flat rolling of steel

Cited by 9 publications

References 7 publications

A Numerical Procedure Based on Orowan’s Theory for Predicting the Behavior of the Cold Rolling Mill Process in Full Film Lubrication

A Numerical Procedure Based on Orowan’s Theory for Predicting the Behavior of the Cold Rolling Mill Process in Full Film Lubrication

Extension of the Freiberg Layer Model by Means of Elastic–Plastic Material Behavior

Extension of the Freiberg Layer Model by Means of Solidification for Roll Casting

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