scholarly journals Modernization of laboratory rolling mill 150 for the formation of students 'studies of automation object research

2021 ◽  
Vol 3 (134) ◽  
pp. 87-98
Author(s):  
Mykhailo Zinchenko ◽  
Oleh Potap ◽  
Maria Rybalchenko ◽  
Ivan Manachyn
Keyword(s):  
Control Systems ◽  
Rolling Mill ◽  
Rolling Force ◽  
Frequency Converter ◽  
Rolling Process ◽  
Gear Ratio ◽  
Educational Process ◽  
Displacement Sensor ◽  
Sensors And Actuators ◽  
Monitor Screen

Studying the operation of automated control systems using computers significantly re-duces the time, but does not give a complete picture of the system on a real object. Therefore, the use of real objects for the study of control systems in the educational process is appropriate and useful. The purpose of the study is to modernize the laboratory rolling mill 150, designed for rolling lead, tin and plasticine, and equip it with sensors and actuators. The manual pressure device of the rolling stand was replaced by an automated one, for which an worm gearbox was additionally installed, which allowed to increase the total gear ratio to 94.5. The thrust screws are moved from the AC motor, which is controlled by the DOP-103BQ operator panel and the MS-300 frequency converter with built-in PLC. As a displacement sensor used photopulse sensor PDF-3. The installed equipment and the developed software for the operator panel and the PLC provided high accuracy of in-stallation of pressure screws in the set position. Additionally, software was developed to measure the power parameters of the rolling process: the rolling force and the electrical parameters of the DC motor of the drive of the rolling stand. The software allows you to configure the board, ie select the type of board, the channels used to measure voltage signals, select measurement ranges, signal color on the graph, signal polling frequency, number of points to display on the graph, parameters of graph coordinate axes. In the process of measurement, the output of signals to the monitor screen is performed simultaneously. Before rolling, the measurement process is started using the keyboard or mouse and the change of parameters is displayed on the screen in real time. At the end of the rolling process, the measurement stops, and the graphs of parameter changes over time remain on the monitor screen, which allows you to quickly analyze the process. The measurement results can be saved in an Excel file and then the file can be viewed. The file stores: the time of measurement of parameters and the values of parameters those were measured. Measurement of power parameters and sizes of rolled products before and after rolling allowed to determine the stiffness of the stand and rolled metal, which is necessary to calculate the transmission coefficients of the automated tuning system of the rolling stand.

Reviews in Dynamic Characteristics of Rolling Interface and Vibration Test/Suppression Methods of Rolling Mill

2020 ◽  
Vol 14 ◽  
Author(s):  
Xiao-bin Fan ◽  
Hao Li ◽  
Yu Jiang ◽  
Bing-xu Fan ◽  
Liang-jing Li
Keyword(s):  
Dynamic Characteristics ◽  
Rolling Mill ◽  
Frequency Conversion ◽  
Vibration Suppression ◽  
Rolling Force ◽  
Rolling Process ◽  
Friction Model ◽  
Time Frequency ◽  
Roll Gap ◽  
Rolling Mill Vibration

Background: Rolling mill vibration mechanism is very complex, and people haven't found a satisfactory vibration control method. Rolling interface is one of the vibration sources of the rolling mill system, and its friction and lubrication state has a great impact on the vibration of the rolling mill system. It is necessary to establish an accurate friction model for unsteady lubrication process of roll gap and a nonlinear vibration dynamic model for rolling process. In addition, it is necessary to obtain more direct and real rolling mill vibration characteristics from the measured vibration signals, and then study the vibration suppression method and design the vibration suppression device. Methods: This paper summarizes the friction lubrication characteristics of rolling interface and its influence on rolling mill vibration, as well as the dynamic friction model of rolling interface, the tribological model of unsteady lubrication process of roll gap, the non-linear vibration dynamic model of rolling process, the random and non-stationary dynamic behavior of rolling mill vibration, etc. At the same time, the research status of rolling mill vibration testing technology and vibration suppression methods were summarized. Time-frequency analysis of non-stationary vibration signals was reviewed, such as wavelet transform, Wigner-Ville distribution, empirical mode decomposition, blind source signal extraction, rolling vibration suppression equipment development. Results: The lubrication interface of the roller gap under vibration state presents unsteady dynamic characteristics. The signals generated by the vibration must be analyzed in time and frequency simultaneously. In the aspect of vibration suppression of rolling mill, the calculation of inherent characteristics should be carried out in the design of rolling mill to avoid dynamic defects such as resonance. When designing or upgrading the mill structure, it is necessary to optimize the structure of the work roll bending and roll shifting system, such as designing and developing the automatic adjustment mechanism of the gap between the roller bearing seat and the mill stand, adding floating support device to the drum shaped toothed joint shaft, etc. In terms of rolling technology, rolling vibration can be restrained by improving roll lubrication, reasonably distributing rolling force of each rolling mill, reducing rolling force of vibration prone rolling mill, increasing entrance temperature, reducing rolling inlet tension, reducing strip outlet temperature and reasonably arranging roll diameter. The coupling vibration can also be suppressed by optimizing the hydraulic servo system and the frequency conversion control of the motor. Conclusion: Under the vibration state, the lubrication interface of roll gap presents unsteady dynamic characteristics. The signal generated by vibration must be analyzed by time-frequency distribution. In the aspect of vibration suppression of rolling mill, the calculation of inherent characteristics should be carried out in the design of rolling mill to avoid dynamic defects such as resonance. It is necessary to optimize the structure of work roll bending and roll shifting system when designing or reforming the mill structure. In rolling process, rolling vibration can be restrained by improving roll lubrication, reasonably distributing rolling force of each rolling mill, increasing billet temperature, reasonably arranging roll diameter and reducing rolling inlet tension. Through the optimization of the hydraulic servo system and the frequency conversion control of the motor, the coupling vibration can be suppressed. The paper has important reference significance for vibration suppression of continuous rolling mill and efficient production of high quality strip products.

Dynamic Response Analysis of Tandem Rolling Mill in Rolling Process

2018 ◽  
Vol 764 ◽  
pp. 391-398
Author(s):  
Xing Han ◽  
Lian Jin Li
Keyword(s):  
Finite Element ◽  
Dynamic Response ◽  
Rolling Mill ◽  
Rolling Force ◽  
Rolling Process ◽  
Steel Pipe ◽  
Response Analysis ◽  
Dynamic Response Analysis ◽  
Finite Element Software ◽  
Seamless Steel

Due to the influence of rolling force fluctuations, tube size changes and material uniformity and other factors, vibration and other phenomenon inevitably occur in the rolling process of tandem rolling mill. This vibration has a great impact on the dynamic stability of the mill and rolling reduction, and will significantly reduce the dimensional accuracy and surface quality of seamless steel pipe. In this paper, the non-linear finite element software ABAQUS is used to simulate the rolling process of seamless steel pipe. First, rolling force of the first frame with the maximum rolling force of PQF rolling mill is calculated. The reliability of rolling force calculated by the finite element method is verified by the test experiment. The dynamic response analysis of the roll is carried out to obtain the dynamic response curve of the roll in the rolling state and to provide technical support for the rolling schedule with the calculated rolling force being the load.

scholarly journals Coupled Vibration Characteristics Analysis of Hot Rolling Mill with Structural Gap

2021 ◽  
Vol 2021 ◽  
pp. 1-10
Author(s):  
Guangxu Zhang ◽  
Jiahan Bao ◽  
Wenhao Li ◽  
Zhichong Wang ◽  
Xiangshuai Meng
Keyword(s):  
Hot Rolling ◽  
Rolling Mill ◽  
Process Model ◽  
Elastic Recovery ◽  
Rolling Force ◽  
Excitation Amplitude ◽  
Work Roll ◽  
Rolling Process ◽  
Structure Model ◽  
Rolling Mills

It is important to study the vibration of rolling mills to improve the stability of rolling production. A dynamic rolling process model is established by considering the elastic recovery of the exit strip and the influence of multiroll equilibrium, and the accuracy of the model is verified by experimental data. On this basis, based on the distribution of friction force in the deformation zone, the rolling force and rolling torque are nonlinearized. In addition, a rolling mill structure model is established by considering the structure gap and a piecewise nonlinear horizontal-vertical-torsional vibration model of the rolling mill is established by combining the structure model and dynamic rolling process model. Finally, the amplitude-frequency characteristics of the work roll under different external excitation amplitude and the dynamic bifurcation characteristics of the work roll under different gaps are analyzed. The study indicates that, by reducing excitation amplitude and structure gap, the system vibration can be reduced. The research results can provide a theoretical reference for further exploration of the coupling vibration of hot rolling mills.

scholarly journals Multiple-Modal-Coupling Modeling and Stability Analysis of Cold Rolling Mill Vibration

2016 ◽  
Vol 2016 ◽  
pp. 1-26 ◽  
Author(s):  
Lingqiang Zeng ◽  
Yong Zang ◽  
Zhiying Gao
Keyword(s):  
Dynamic Model ◽  
Rolling Mill ◽  
Process Model ◽  
Rolling Force ◽  
Rolling Process ◽  
Dynamic Responses ◽  
System Stability ◽  
Force Model ◽  
Structure Model ◽  
Rolling Mill Vibration

An effective dynamic model is the basis for studying rolling mill vibration. Through analyzing characteristics of different types of vibration, a coupling vibration structure model is established, in which vertical vibration, horizontal vibration, and torsional vibration can be well indicated. In addition, based on the Bland-Ford-Hill rolling force model, a dynamic rolling process model is formulated. On this basis, the rolling mill vertical-torsional-horizontal coupled dynamic model is constructed by coupling the rolling process model and the mill structure model. According to this mathematical model, the critical rolling speed is determined and the accuracy of calculated results is verified by experimental data. Then, the interactions between different subsystems are demonstrated by dynamic responses in both time and frequency domains. Finally, the influences of process parameters and structure parameters on system stability are analyzed. And a series of experiments are conducted to verify the correctness of these analysis conclusions. The results show that the vertical-torsional-horizontal coupled model can reasonably characterize the coupling relationship between the mill structure and the rolling process. These studies are helpful for formulating a reasonable technological procedure of the rolling process and determining a feasible dynamic modification strategy of the structure as well.

Anslysis of the 5-m Heavy Plate Mill Stand Based on MSC.Marc Finite Element Method

2011 ◽  
Vol 189-193 ◽  
pp. 1844-1848
Author(s):  
Zhen Yi Huang ◽  
Min Xia Chen ◽  
Chang Hong Li ◽  
Sheng Fu Wu ◽  
Wei Wang ◽  
...  
Keyword(s):  
Finite Element ◽  
Rolling Mill ◽  
Rolling Force ◽  
Rolling Process ◽  
Simulation Software ◽  
Stress And Strain ◽  
Plate Mill ◽  
Heavy Plate ◽  
System Pressure ◽  
Roller System

The stand is the largest and most important part in rolling-mill components.It bears tremendous rolling force, instant impact and part of the rolling torque during the rolling process .In addition ,roller system ,pressure and balance system also installed in it. Therefore, rolling mill must be equipped with sufficient strength and stiffness to ensure the safety of mill equipment and accuracy of the size of products. In this paper, It uses the finite element simulation software MSC.Marc to simulate and analyze the 3-D finite 5-m heavy plate mill housing of Baosteel . which can provides effective theoretical basis to the optimization of technology establish and the safety of equipment. The simulation results can be used to verify the accuracy of stress and strain field measured data for the mill frame, It also can infer parts of rolling mill which is not detected and unpredictable of the stress and strain states, and further to learn about weak parts of frame in stiffness and strength facets.

scholarly journals Thin Strip Profile Control Capability of Roll Crossing and Shifting in Cold Rolling Mill

2013 ◽  
Vol 773-774 ◽  
pp. 70-78 ◽  
Author(s):  
Abdulrahman Aljabri ◽  
Zheng Yi Jiang ◽  
Dong Bin Wei ◽  
Xiao Dong Wang ◽  
Hasan Tibar
Keyword(s):  
Cold Rolling ◽  
Rolling Mill ◽  
Rolling Force ◽  
Work Roll ◽  
Rolling Process ◽  
Thin Strip ◽  
Strip Rolling ◽  
Strip Shape ◽  
Strip Profile ◽  
Profile Control

Controlling cold strip profile is a difficult and significant problem has been found in industry during thin strip rolling. At present choosing the new type of strip rolling mill is the one of main methods to control the strip shape quality in cold rolling. The influences of rolling process parameters such as the work roll cross angle and work roll shifting on the strip shape and profile of thin strip are recognised throughout this study. The results show that the roll crossing and shifting is efficient way to control the strip shape. The increase of the work roll crossing angle would lead to improve the strip profile significantly by decreasing the exit strip crown and edge drop. The strip profile would be enhanced if the axial roll shifting was increased. Moreover, the total rolling force was analysed in detail by changing the roll cross angle and axial shifting roll.

Advanced Flatness Control Strategies for Multivariable Optimisation Flatness Control System of Foil Rolling Mill

2013 ◽  
Vol 655-657 ◽  
pp. 1450-1455 ◽  
Author(s):  
Liang Hao ◽  
H.S. Di ◽  
D.Y. Gong ◽  
D.B. Wei ◽  
Z.Y. Jiang
Keyword(s):  
Control System ◽  
Control Systems ◽  
Rolling Mill ◽  
Rolling Force ◽  
Control Strategies ◽  
Bending Force ◽  
Foil Rolling ◽  
Flatness Control ◽  
Application Fields ◽  
Flatness Error

In cold strip or foil rolling, flatness control is an integral part of modern mill. This paper introduces two typical flatness control systems, pattern recognisation flatness control system and multivariable flatness control. It is found that the latter is effective and has wider application fields. The FEM models of its core parameters, flatness actuator efficiency, are constructed. Influencing factors, such as the rolling force, bending force as well as the tilting force are discussed. Control strategies are proposed for foil rolling. The results demonstrate that the control strategies can reduce flatness error and improve flatness quality.

scholarly journals The Chosen Aspects of Skew Rolling of Hollow Stepped Shafts

Materials ◽  
2021 ◽  
Vol 14 (4) ◽  
pp. 764
Author(s):  
Jarosław Bartnicki ◽  
Yingxiang Xia ◽  
Xuedao Shu
Keyword(s):  
Cross Section ◽  
Rolling Mill ◽  
Metal Flow ◽  
Experimental Tests ◽  
Rolling Process ◽  
Numerical Control ◽  
Technological Parameters ◽  
Flow Mechanisms ◽  
The Individual ◽  
Skew Rolling

The paper presents chosen aspects of the skew rolling process of hollow stepped products with the use of a skew rolling mill designed and manufactured at the Lublin University of Technology. This machine is characterized by the numerical control of spacing between the working rolls and the sequence of the gripper axial movement, which allows for the individual programming of the obtained shapes of parts such as stepped axles and shafts. The length of these zones and the values of possibly realizable cross-section reduction and obtained outlines are the subject of this research paper. The chosen results regarding the influence of the technological parameters used on the course of the process are shown in the present study. Numerical modelling using the finite element method in Simufact Forming, as well as the results of experimental tests performed in a skew rolling mill, were applied in the conducted research. The work takes into account the influence of cross-section reduction of the hollow parts and the feed rate per rotation on the metal flow mechanisms in the skew rolling process. The presented results concern the obtained dimensional deviations and changes in the wall thickness determining the proper choice of technological parameters for hollow parts formed by the skew rolling method. Knowledge about the cause of the occurrence of these limitations is very important for the development of this technology and the choice of the process parameters.

scholarly journals Vibration Characteristics of Hot Rolling Mill Rolls Based on Elastoplastic Hysteretic Deformation

Metals ◽  
2021 ◽  
Vol 11 (6) ◽  
pp. 869
Author(s):  
Rongrong Peng ◽  
Xingzhong Zhang ◽  
Peiming Shi
Keyword(s):  
Hot Rolling ◽  
Internal Resonance ◽  
Rolling Mill ◽  
Rolling Force ◽  
Subharmonic Resonance ◽  
Force Model ◽  
Maximum Lyapunov Exponent ◽  
Vibration System ◽  
Hot Rolling Mill ◽  
Rolling Mill Vibration

Based on the analysis of the influence of roll vibration on the elastoplastic deformation state of a workpiece in a rolling process, a dynamic rolling force model with the hysteresis effect is established. Taking the rolling parameters of a 1780 mm hot rolling mill as an example, we analyzed the hysteresis between the dynamic rolling force and the roll vibration displacement by varying the rolling speed, roll radius, entry thickness, front tension, back tension, and strip width. Under the effect of the dynamic rolling force and considering the nonlinear effect between the backup and work rolls as well as the structural constraints on the rolling mill, a hysteretic nonlinear vertical vibration model of a four-high hot rolling mill was established. The amplitude-frequency equations corresponding to 1/2 subharmonic resonance and 1:1 internal resonance of the rolling mill rolls were obtained using a multi-scale approximation method. The amplitude-frequency characteristics of the rolling mill vibration system with different parameters were studied through a numerical simulation. The parametric stiffness and nonlinear stiffness corresponding to the dynamic rolling force were found to have a significant influence on the amplitude of the subharmonic resonance system, the bending degree of the vibration curve, and the size of the resonance region. Moreover, with the change in the parametric stiffness, the internal resonance exhibited an evident jump phenomenon. Finally, the chaotic characteristics of the rolling mill vibration system were studied, and the dynamic behavior of the vibration system was analyzed and verified using a bifurcation diagram, maximum Lyapunov exponent, phase trajectory, and Poincare section. Our research provides a theoretical reference for eliminating and suppressing the chatter in rolling mills subjected to an elastoplastic hysteresis deformation.

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