scholarly journals The Analytic Study on the Heavy Steel Plate Snake Rolling with the Same Roll Diameters

2018 ◽  
Vol 2018 ◽  
pp. 1-11
Author(s):  
Lian-yun Jiang ◽  
Qing-cheng Meng ◽  
Chun-jiang Zhao ◽  
Shou-xin Wang ◽  
Yan-wei Liu
Keyword(s):  
Steel Plate ◽  
Rolling Force ◽  
Rolling Process ◽  
Slip Zone ◽  
Mechanical Parameters ◽  
Rolling Method ◽  
Set Up ◽  
Rolling Torque ◽  
Inner Region ◽  
Rolling Deformation

The deformation in the inner region along the thickness of the heavy steel plate can be improved by snake rolling method. Then the microstructure and property will be refined and the crack in the inner region may be avoided. Therefore, the in-depth research on snake rolling method mechanics parameter modeling should be conducted to guide production. A snake rolling process with the same roll diameters and different angular velocity was conducted in this paper. The rolling deformation zone will be divided into back slip zone, front slip zone, cross shear zone, and reverse deflection zone according to the direction of the friction during the snake rolling process. The four zones may not exist at the same time. The boundary conditions of existence of the back slip zone, front slip zone, and cross shear zone were established according to the relationship between threading angle and neutral angle. The calculating models which were used to calculate the snake rolling mechanical parameters including the rolling force and rolling torque were set up. The calculated models of unit compressive pressure in the four zones were set up by the slab method, and on this basis the accurate calculating models of the rolling force and rolling torque were set up according to the composition of the rolling deformation zone and the boundary condition. The mechanical parameters were calculated by the analytical method and the numerical method, and the relative deviation is less than 6% which can satisfy the industrial requirement. The present analytical model can predict the characteristics during snake rolling easily and quickly and it is also suitable for online control applications.

The analytic study on the heavy steel plate snake rolling with the different roll diameters

2019 ◽  
Vol 116 (4) ◽  
pp. 402 ◽  
Author(s):  
Qing-cheng Meng ◽  
Lian-yun Jiang ◽  
Li-feng Ma ◽  
Jun-yi Lei
Keyword(s):  
Shear Zone ◽  
Deformation Zone ◽  
Steel Plate ◽  
Rolling Force ◽  
Slip Zone ◽  
Mechanical Parameters ◽  
Rolling Method ◽  
Rolling Torque ◽  
Inner Region ◽  
Rolling Deformation

The deformation in the inner region along the thickness of the heavy steel plate can be improved by snake rolling method. Then the microstructure and property will be refined and the crack in the inner region may be avoided. So the in-depth research on snake rolling method mechanics parameter modeling should be conducted to guide production. The rolling deformation zone will be divided into back slip zone, cross shear zone, front slip zone and reverse deflection zone according to the direction of the friction during the snake rolling process. The four zones may not exist at the same time. The boundary conditions of existence of the back slip zone, cross shear zone and front slip zone were established by calculating the position of neutral point by a special method. The calculating models which were used to calculate the snake rolling mechanical parameters including the rolling force and rolling torque were setup. The calculated models of unit compressive pressure in the four zones were setup by the slab method, and at this basis, the accurate calculating models of the rolling force and rolling torque were setup according to the composition of the rolling deformation zone and the boundary condition. The mechanical parameters were calculated by the analytic method and the numerical method, and the relative deviation is less than 5% which can satisfy the industrial requirement. The present analytical model can predict the characteristics during snake rolling easily and quickly and it is also suitable for online control applications.

The mechanical parameters modeling of heavy steel plate snake/gradient temperature rolling with the same roll diameters

2020 ◽  
Vol 117 (3) ◽  
pp. 301
Author(s):  
Lian-Yun Jiang ◽  
Tao Zhen ◽  
Guo Yuan ◽  
Jin-Bo Huang ◽  
Yao-Yu Wei ◽  
...  
Keyword(s):  
Shear Zone ◽  
Steel Plate ◽  
Rolling Force ◽  
Slip Zone ◽  
Analytic Model ◽  
Mechanical Parameters ◽  
Ansys Software ◽  
Relative Deviation ◽  
Maximum Relative Deviation ◽  
Rolling Torque

The grains in the center of the heavy steel plate can be refined by the snake/gradient temperature rolling, and the deformation penetration, the microstructure, and the properties of the steel plate will be improved. The existing rolling mechanical models are not suitable for the snake/gradient temperature rolling, so it is necessary to establish the mechanical parameters model of the snake/gradient temperature rolling to instruct production. The yield criterion of rolled material was modified based on the idea of equivalent flow stress. The element stress analyses were carried out based on the uniform normal stress and nonuniform shear stress in the vertical sides of each slab. Then the equilibrium equation of the unit pressure based on the slab method was established on this basis. The deformation region was divided into three layers (the top layer, the bottom layer, and the central layer) and maximum four zones (back slip zone, front slip zone, cross shear zone, and reverse deflection zone) according to the temperature distribution and position of the neutral point, and then the 12 zones were formed during the snake/gradient temperature rolling. The boundary conditions of the existence of the back slip zone, the front slip zone, and the cross shear zone were established according to the relationship between the threading angle and the neutral angle. The accurate mechanical parameters model of the rolling force and rolling torque of the snake/gradient temperature rolling with the same roll diameters was set up on this basis. The ANSYS software has been used in the rolling process simulation by many scholars, and the calculating precision has been verified. So the rolling processes were simulated by the ANSYS software to validate the model precision. The results show that the maximum relative deviation of the rolling force analytic model is less than 7% compared with the numerical method, and the maximum relative deviation of the rolling torque analytic model is less than 11% compared with the measured results. The mechanical parameters model can accurately predict the rolling force and rolling torque during the snake/gradient temperature rolling with the same roll diameters, so as to provide a theoretical basis for the design of rolling mill and the setup of the process parameters.

scholarly journals New Numerical Solution of von Karman Equation of Lengthwise Rolling

2015 ◽  
Vol 2015 ◽  
pp. 1-20 ◽  
Author(s):  
Rudolf Pernis ◽  
Tibor Kvackaj
Keyword(s):  
Contact Stress ◽  
Rolling Force ◽  
Rolling Process ◽  
Normal Contact Stress ◽  
Normal Contact ◽  
Circular Arch ◽  
Relative Stress ◽  
Roll Flattening ◽  
Polygonal Curve ◽  
Rolling Torque

The calculation of average material contact pressure to rolls base on mathematical theory of rolling process given by Karman equation was solved by many authors. The solutions reported by authors are used simplifications for solution of Karman equation. The simplifications are based on two cases for approximation of the circular arch: (a) by polygonal curve and (b) by parabola. The contribution of the present paper for solution of two-dimensional differential equation of rolling is based on description of the circular arch by equation of a circle. The new term relative stress as nondimensional variable was defined. The result from derived mathematical models can be calculated following variables: normal contact stress distribution, front and back tensions, angle of neutral point, coefficient of the arm of rolling force, rolling force, and rolling torque during rolling process. Laboratory cold rolled experiment of CuZn30 brass material was performed. Work hardening during brass processing was calculated. Comparison of theoretical values of normal contact stress with values of normal contact stress obtained from cold rolling experiment was performed. The calculations were not concluded with roll flattening.

scholarly journals Study of Wire Deformation Characterization and Size Effects during the Micro-Flat-Rolling Process

Metals ◽  
2020 ◽  
Vol 10 (3) ◽  
pp. 405 ◽  
Author(s):  
Haibo Xie ◽  
Ken-ichi Manabe ◽  
Zhengyi Jiang
Keyword(s):  
Surface Roughness ◽  
Contact Area ◽  
Rolling Process ◽  
Lateral Spread ◽  
Curvature Radius ◽  
Element Simulation ◽  
Flat Rolling ◽  
Set Up ◽  
Rolling Deformation

A comprehensive research on the flat rolling deformation characterization of microwire has been conducted systematically through finite element simulation and testified by the results from the experimental analysis. The obtained results are compared in terms of lateral spread, geometrical characteristic, contact area width and surface roughness considering the effects of pass reduction and initial wire diameter. The size effect has been identified and surface layer modeling has been set up based on surface grain share and grain size distribution. The numerical method combined with varied flow stress has been verified by experimental value with a maximum difference of 3.7% for the 1.5 mm wire. With the increase of the height reduction, the curvature radius is decreased while the lateral spread and contact area width are increased. Surface roughness evolution in the range of 0.52–0.85 µm for the rolled wire has also been investigated.

scholarly journals Perancangan Mekanisme Pelurusan Kawat SAE 304 (UNS S30400) Galvanized Menggunakan Prinsip Pengerolan

2021 ◽  
Vol 5 (2) ◽  
pp. 1-7
Author(s):  
Herman Susanto ◽  
Sunardi Tjandra
Keyword(s):  
Plastic Deformation ◽  
Raw Materials ◽  
Rolling Force ◽  
Rolling Process ◽  
Empirical Method ◽  
Basic Process ◽  
Roll Bending ◽  
Small Industry ◽  
Rolling Method ◽  
Vertical Gap

Wire is a complement material on the manufacturing product. Therefore, the wire processes usually bestowed to the middle-low industry. Cutting and straightening wire processes are the most basic process for wire materials. In the middle-small industry, demand of wire materials is 150 kg per day. Seeing this potential, the design of a wire straightening mechanism for middle-low industries is necessary to maximize productivity. The main purpose of wire straightening mechanism design is calculating roll diameters and placement to obtain appropriate rolling force. In designing this wire straightening mechanism, the raw materials are used 3 mm SAE 304 (UNS S30400) Galvanized. The rolling method used in this mechanism is Three-Roll Bending. The empirical method is used on this analysis. Based on the analytical results, roll used on this mechanism are 5 pieces or equal with 3 cycle of rolling process with 40 mm of diameters. The vertical gap between center of rolls is 41.5 mm with 54 mm horizontal gap. Rolling force produced by the analytical roll dimension is 1608.69 N/cycle and that’s enough to give plastic deformation on the 3 mm SAE 304 (UNS S30400) Galvanized wire.

scholarly journals A New Method of Manufacturing Hollow Shafts via Flexible Skew Rolling

2021 ◽  
Vol 2101 (1) ◽  
pp. 012010
Author(s):  
Xiaoqing Cao ◽  
Baoyu Wang ◽  
Wei Guo ◽  
Zhidong Ju
Keyword(s):  
Rolling Force ◽  
Rolling Process ◽  
Fe Model ◽  
Forming Process ◽  
Hollow Shaft ◽  
Process Adjustment ◽  
Rolling Load ◽  
Rolling Torque ◽  
Skew Rolling ◽  
Hollow Shafts

Abstract The existing rolling process of large and long axle parts, such as the cross wedge rolling (CWR) process, requires special molds and larger equipment. Flexible skew rolling (FSR) hollow shafts with mandrel is a near net-shape rolling technology which can achieve the diversified production of rolled parts without special molds. It has significant advantages such as small equipment tonnage, small die size, low rolling load, simple process adjustment, and especially suitable for multi-variety and small-batch production. This paper proposes hollow train shafts formed by FSR with mandrel. Reasonable parameters were selected for experiments, and the forming process was calculated by finite element (FE) software. The experimental results are consistent with the simulation results, indicating that the FE model is reliable. The rolling force and rolling torque are analyzed by simulation. Finally, the microstructure of different positions of the rolled-piece is analyzed, and the microstructure of the rolled part is refined. It is provide a feasible scheme for the rolling of large hollow shaft parts.

Chatter in the Strip Rolling Process, Part 1: Dynamic Model of Rolling

1998 ◽  
Vol 120 (2) ◽  
pp. 330-336 ◽  
Author(s):  
I-S. Yun ◽  
W. R. D. Wilson ◽  
K. F. Ehmann
Keyword(s):  
Dynamic Model ◽  
Coulomb Friction ◽  
Rolling Force ◽  
Rolling Process ◽  
Rate Of Change ◽  
Two Dimensional ◽  
Entry And Exit ◽  
Strip Rolling ◽  
Coulomb Friction Law ◽  
Rolling Torque

This paper presents the development of a new dynamic model of the rolling process which provides estimates of the variations in exit gage, strip speed and tension at entry and exit, rolling force and rolling torque in response to variations in roll separation as well as the rate of change of the roll spacing. This two-dimensional dynamic model employs the Tresca friction factor approach instead of Amontons-Coulomb friction law.

Mechanics Analysis and Numerical Simulation on the Precise Forming Process of Spline Cold Rolling

2008 ◽  
Vol 575-578 ◽  
pp. 416-421 ◽  
Author(s):  
Yong Tang Li ◽  
Jian Li Song ◽  
Da Wei Zhang ◽  
Quan Gang Zheng
Keyword(s):  
Numerical Simulation ◽  
Cold Rolling ◽  
Theoretical Basis ◽  
Rolling Force ◽  
Rolling Process ◽  
Average Pressure ◽  
Forming Process ◽  
Mechanics Analysis ◽  
Simulation And Experiment ◽  
Set Up

The forming process of spline cold rolling was analyzed. The unit average pressure, contact area and rolling force in the cold rolling precision forming process were analyzed and solved. The mechanical and mathematical model has been set up on the basis of the analysis. The numerical simulation of spline cold rolling process was carried out. The results obtained by comparison of theoretical analysis, numerical simulation and experiment provide a theoretical basis for the study and application of spline cold rolling process.

Online Calculation Model of Rolling Force for Mg Alloy Rolling Process

2013 ◽  
Vol 753-755 ◽  
pp. 245-248
Author(s):  
Jing Na Sun ◽  
Tao Xue ◽  
Zhi Yuan Guo
Keyword(s):  
Finite Difference Method ◽  
High Speed ◽  
Rolling Force ◽  
New Products ◽  
Rolling Process ◽  
Calculation Model ◽  
Mg Alloy ◽  
Product Profile ◽  
The Finite Difference Method ◽  
Set Up

Rolling force is critical to realize the industrialized production of the rolled mg alloy sheets especially more than 1500 mm width which affects the mill set-up schedule, the thickness of the rolled metal, and the final product profile. An online calculation model of rolling force with high precision and high speed has also been developed with the finite difference method (FDM) in this paper which can provides a good guidance for the enhancement of product precision and the development of new products.

Effect of Drive Roll Rotation Speed on Ring Rolling Process

2011 ◽  
Vol 189-193 ◽  
pp. 2586-2592
Author(s):  
Jie Zhou ◽  
Xiao Tao Gong ◽  
Xiao Bing Yang ◽  
Wu Jiao Xu
Keyword(s):  
Rotation Speed ◽  
Rolling Force ◽  
Metal Flow ◽  
Equivalent Plastic Strain ◽  
Rolling Process ◽  
Ring Rolling ◽  
Rolled Ring ◽  
Rolling Torque ◽  
Ring Rolling Process ◽  
Drive Roll

Based on the platform ABAQUS, 3-D FEA model for ring rolling has been constructed to investigate the effect of drive roll rotation speed on the metal flow in the ring rolling process. It can be seen clearly that the axial metal flow in the outside diameter of the rolled ring increases with the increasing of drive roll rotation speed and with the decreasing of the feeding magnitude per revolution , which causes the increasing of fishtail coefficient FT and maximum spread coefficient and in turn makes the quality deterioration of end-plane in the rolled ring. The rolling force and rolling torque necessary to execute the rolling process are reduced when the drive roll rotation speed is elevated, which results in the lower requirement for the characteristic of force and energy in the rolling machine. Besides that, average equivalent plastic strain PEEQ also increases, which indicates the enhancement of plastic deformation and is beneficial to the improvement of the mechanical property of the formed ring. But one point that we should pay attention is that uneven deformation and possibility of the inner defects in the rolled ring might be increased with the increasing of the drive roll rotation speed.

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