Simulation of plate rolling process using finite element method

Kumar, Alok; Rath, Sushant; Kumar, Manoj

doi:10.1016/j.matpr.2020.11.050

Cited by 15 publications

(14 citation statements)

References 13 publications

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“…). [34][35][36][37][38] For the given material pairing, valid data from friction experiments are not available. Therefore, a coefficient of friction within these limits was assumed as a compromise.…”

Section: Application Discussion and Correlation With Measured Process...mentioning

confidence: 99%

“…The coefficient of friction used in the literature exhibits a broad spectrum, which ranges from 0.3 (in Razny et al and Trull et al) or 0.35 (in Ding et al and Shou‐yuan et al) to 0.8 (in Kumar et al). [ 34–38 ] For the given material pairing, valid data from friction experiments are not available. Therefore, a coefficient of friction within these limits was assumed as a compromise.…”

Section: Application Discussion and Correlation With Measured Process...mentioning

confidence: 99%

See 1 more Smart Citation

Toward a 2D/3D Finite‐Element–Based Digital Shadow for the Approximation of Metrologically Inaccessible Dynamic Fields of State Variables during Heavy Plate Rolling

Nemetz

Parteder

Reimer

et al. 2023

steel research int.

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Heavy plates are products of global economic relevance. Due to the high requirements for this semifinished product, the trend in heavy plate processing is toward providing ever higher quality steels that, for instance, combine a predefined yield point, good weldability, and, at the same time, predefined toughness properties. Unprecedented quality requirements in steel processing can only be met if technologically relevant parameters, such as temperature, are guaranteed to be kept within a narrow tolerance range during the hotrolling process, one of the most decisive steps within the production chain for heavy plates. Within the heavy plate hot-rolling process, often performed in a reversing four-high mill stand consisting of a pair of work rolls and a pair of backup rolls, various production steps like rolling passes, descaling sequences, and cooling periods, determine the plate's temperature evolution. [1] In parallel, temperature evolution affects the microstructure and, thus, associated physical properties of the final product, such as hardness and toughness. [2] It is, therefore, of utmost importance to consider the evolution of the temperature field inside the heavy plate as a specification when planning the entire process that reaches from the slab's exit from the furnace to the last pass.All in all, the production steps of hot rolling govern the plate temperature in two fundamentally different scenarios: sufficiently far from the roll bite, the plate temperature decreases moderately through air cooling or abruptly on the surface of the plate through contact with water which is applied locally in the form of high-pressure jets provided by a water descaling unit. Inside the roll bite, the plastic deformation is accompanied by heat generation inside the plate, and simultaneously the contacting cooler work rolls reduce the temperature at its surfaces. These and other thermomechanical effects can hardly be measured, which is the reason why models are utilized for better insight. As digital transformation has become a significant innovation driver, a digital representation of the process in the form of an integrated digital model, digital shadow, or digital twin has to cover these potentially interfering thermomechanical aspects. [3,4] Modeling and simulation have been integral to the research and development of rolling processes for decades. An incomplete but representative selection of milestones, in chronological order, is intended to outline the road to comprehensive modeling approaches available today: The journey started with basic

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Section: Application Discussion and Correlation With Measured Process...mentioning

confidence: 99%

Section: Application Discussion and Correlation With Measured Process...mentioning

confidence: 99%

Toward a 2D/3D Finite‐Element–Based Digital Shadow for the Approximation of Metrologically Inaccessible Dynamic Fields of State Variables during Heavy Plate Rolling

Nemetz

Parteder

Reimer

et al. 2023

steel research int.

View full text Add to dashboard Cite

show abstract

“…The result shows that using a concave profile which corresponds to a negative roll can reduce the occurrence of edge cracks in the strip during cold rolling. Kumar et al 11 used the finite element software Deform-3D to investigate the roll bite deformation during rolling of microalloyed and plain carbon steels, discussed the effects of temperature and friction coefficient and performed rolling test. It was found that the peak stress of microalloyed steel was 13%–25% higher than ordinary carbon steel during roll bite.…”

Section: Introductionmentioning

confidence: 99%

“…The primary focus of research was to simulate rolling processes with different finite element softwares, then to analyze the influence of various process parameters on the stress–strain relationship and materials’ changes about internal structure and organizational performance during rolling. 14–16 However, researches on the porosity defects of Al-Si alloys have been relatively scarce.…”

Section: Introductionmentioning

confidence: 99%

Effect of process parameters on porosity defects in Al-Si alloy hot rolling

Zhao

Jin

Bao

2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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Hot-rolled Al-Si alloy sheets are used to be formed Al alloy welding additions and cladding materials that are widely used in the aviation, automotive, and air conditioning industries. However, if parameters of hot-rolling process are not properly selected, porosity defects during casting will lead to cracks or fractures in Al-Si alloy sheets. This study based on meso-damage theory and established a damage equation describing porosity defects in the hot rolling process. The parameters of GTN (Gurson-Tvergaard-Needleman) void defect evolution, including the volume fraction of voids in different periods, the plastic equivalent variation of void nucleation, the standard variance of equivalent variation of void nucleation, and the correction coefficient of the material, are determined in this study. A finite element model of the porosity defects is developed based on the determined parameters. The finite element method is used to analyze the effect of different process parameters on the porosity defects and cracks in Al-Si alloy sheets during hot rolling, then we performed the hot rolling test to validate the results. The results show that the void stress and diameter are reduced and the quality of porosity defects is improved by decreasing rolling reductions and increasing the temperature. The optimized process parameters were a 20% depression and a temperature of 550°C.

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“…In the literature, there are some investigations about the hot rolling process using DEFORM-3D: Kumar et al [16] studied the roll bite deformation during a plate rolling process of a microalloyed grade steel and they found that the predicted roll force agreed well with the measured values; Faini et al [17] investigated the effects of the hot rolling main parameters (i.e., percentage of reduction, cooling time, etc.) on void closure index of 316L stainless steel.…”

Section: Introductionmentioning

confidence: 99%

3D-FEM Simulation of Hot Rolling Process and Characterization of the Resultant Microstructure of a Light-Weight Mn Steel

et al. 2021

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Computational simulation has become more important in the design of thermomechanical processing since it allows the optimization of associated parameters such as temperature, stresses, strains and phase transformations. This work presents the results of the three-dimensional Finite Element Method (FEM) simulation of the hot rolling process of a medium Mn steel using DEFORM-3D software. Temperature and effective strain distribution in the surface and center of the sheet were analyzed for different rolling passes; also the change in damage factor was evaluated. According to the hot rolling simulation results, experimental hot rolling parameters were established in order to obtain the desired microstructure avoiding the presence of ferrite precipitation during the process. The microstructural characterization of the hot rolled steel was carried out using optical microscopy (OM), scanning electron microscopy (SEM) and X-ray diffraction (XRD). It was found that the phases present in the steel after hot rolling are austenite and α′-martensite. Additionally, to understand the mechanical behavior, tensile tests were performed and concluded that this new steel can be catalogued in the third automotive generation.

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Simulation of plate rolling process using finite element method

Cited by 15 publications

References 13 publications

Toward a 2D/3D Finite‐Element–Based Digital Shadow for the Approximation of Metrologically Inaccessible Dynamic Fields of State Variables during Heavy Plate Rolling

Toward a 2D/3D Finite‐Element–Based Digital Shadow for the Approximation of Metrologically Inaccessible Dynamic Fields of State Variables during Heavy Plate Rolling

Effect of process parameters on porosity defects in Al-Si alloy hot rolling

3D-FEM Simulation of Hot Rolling Process and Characterization of the Resultant Microstructure of a Light-Weight Mn Steel

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