Analysis of Metal Flow and Deformation Features during Continuous Tube Rolling Process with Mandrel Mill

2011 ◽  
Vol 189-193 ◽  
pp. 2376-2381
Author(s):  
Yuan De Yin ◽  
Sheng Zhi Li ◽  
Yong Lin Kang ◽  
Lan Wei Hu
Keyword(s):  
Wall Thickness ◽  
Deformation Zone ◽  
Early Stage ◽  
Metal Flow ◽  
Equivalent Plastic Strain ◽  
Rolling Process ◽  
Lateral Spread ◽  
Thickness Reduction ◽  
Continuous Rolling ◽  
Stress Strain

With the aid of commercial FE code MSC.SuperForm, the structural steel tube continuous rolling process of a typical hollow tube specification 152.5×12.5mm is simulated based on Bao Steel 152.5 main pass sequence of 140mm 8-stand mandrel mill, and the distribution characteristics of stress/strain, outline lateral spread, temperature changes of workpiece in continuous rolling process and distribution of stress/strain, friction of workpiece in deformation zone are analyzed. Analysis results indicate that deformation of workpiece along the width of the groove, especially at the top and the bottom of the groove is highly inhomogeneous due to the unequal draught and the longitudinal stress of special position (the top and the bottom of the groove) of workpiece is always an alternate state, in a tensile-compressive-tensile manner, and has a distinct rule. In the first stand, outline dimension of workpiece gradually increases during reducing process and early stage of wall thickness reduction, but it gradually decreases during middle-late stage of wall thickness reduction and tends towards stability at last. It is inhomogeneous that distribution of unit compressive stress and longitudinal strain of workpiece in deformation zone, and contact stress and total equivalent plastic strain are maximal in inner surface of workpiece contacting with mandrel. Temperature difference between the outer and the inner surfaces of workpiece is obvious.

Influence of Wall Thickness Fluctuation of Pierced Shell on Continuous Tube Rolling Process of Semi-Floating Mandrel Mill

2011 ◽  
Vol 189-193 ◽  
pp. 2382-2386
Author(s):  
Yuan De Yin ◽  
Sheng Zhi Li ◽  
Yong Lin Kang ◽  
Yang Hua Li ◽  
Gong Ming Long ◽  
...  
Keyword(s):  
Wall Thickness ◽  
Rolling Force ◽  
Metal Flow ◽  
Equivalent Plastic Strain ◽  
Rolling Process ◽  
Steel Tube ◽  
Transverse Wall ◽  
Tube Rolling ◽  
Boiler Steel ◽  
Rolling Moment

In continuous tube rolling process, wall thickness reduction per stand will be changed due to wall thickness fluctuation of pierced shell caused by piercing process, which results in changes in metal flow conditions and affects force parameters, deformation parameters, especially transverse wall thickness precision of rolled hollow tube. In this paper, with the aid of commercial FE code MSC.SuperForm, the high pressure boiler steel tube continuous rolling process of a typical hollow tube specification 133.0×4.0mm are simulated based on 133 main pass sequence of 89mm 6-stand semi-floating mandrel mill, and force parameters, equivalent plastic strain, transverse wall thickness precision, outline dimension and real roundness of rolled hollow tube are analyzed and compared on the condition of two different wall thicknesses of pierced shell. Analysis results indicate that force parameters increase with wall thickness of pierced shell, maximal rolling force, rolling moment and mandrel axial force increase 10% or so in the first three stands when rolling pierced shell of wall thickness 11.5mm compared to that of wall thickness 10.5mm. When rolling pierced shell of wall thickness 10.5mm, there exist front and back tensions among the third, the fourth and the fifth stands and outline dimension and real roundness of rolled hollow tube is slightly better. However, transverse wall thickness of rolled hollow tube at the bottom of groove is pulled thin obviously.

scholarly journals Investigation of Slip Occurrence in the Ring Rolling Process

2019 ◽  
Vol 291 ◽  
pp. 02006
Author(s):  
Andrzej Gontarz ◽  
Piotr Surdacki
Keyword(s):  
Wall Thickness ◽  
Failure Modes ◽  
Rolling Process ◽  
Ring Rolling ◽  
Thickness Reduction ◽  
Main Stage ◽  
Forming Process ◽  
Limit Values ◽  
Ring Shape ◽  
Ring Rolling Process

Ring rolling is a hot forming process for producing rings that have large diameters when compared to their cross sections. This process is very dynamic and involves considerable variations in ring shape and size. One of the failure modes in ring rolling processes is slip that occurs when a thickness reduction, exceeds the limit value. The thickness reduction depends on the tool speed and dimensions as well as ring size, and varies over time. This paper reports results of a study investigating the thickness reduction with respect to slip occurrence. In terms of wall thickness reduction, the process can be divided into three distinct stages (excluding the sizing stage): (i) initial stage corresponding to the first revolution of the roll, (ii) main stage, when the proper ring rolling takes place, (iii) final stage, when the main roll does not move in an axial direction but the ring is being formed during one revolution of the tool. It has been found that the most slip-prone moment is the end of the second and the beginning of the third stage of the ring rolling process, when the wall thickness reduction is the highest. Based on a comparison of the calculated thickness reduction and its limit values, it could be predicted whether slip would occur, and if so – in what stage of the rolling process. Numerical results and experimental findings are in good agreement.

Study on Metal Flow in the Finish Rolling Process of Large-Sized H-Beam

2014 ◽  
Vol 602-605 ◽  
pp. 705-708
Author(s):  
Jin Hong Ma ◽  
Bin Tao ◽  
Xiao Han Yao
Keyword(s):  
Metal Flow ◽  
Rolling Process ◽  
Production Data ◽  
Fe Model ◽  
Continuous Rolling ◽  
Finish Rolling ◽  
Deformation Law ◽  
Hot Continuous Rolling ◽  
H Beam ◽  
Deform 3D

According to the production data of a rolling H-beam factory, the FE model of hot continuous rolling process of H-beam is built. With the FEM software of DEFORM-3D, the continuous rolling of H-beam was simulated. On base of simulation result, the metal flow and deformation law are discussed. Because of the flange and web is deformed in the different deformation zone, the metal flow law of flange and web is complex, especially the metal of the conjunction of flange and web. In this paper, the metal flow of large-sized H-beam in finishing rolling process is analyzed.

Influence of Roll Speed Schedule on Transverse Wall Thickness Evenness of Shell Elongated by Mandrel Mill

2010 ◽  
Vol 654-656 ◽  
pp. 1311-1314 ◽  
Author(s):  
Sheng Zhi Li ◽  
Zhi Chao Zhang ◽  
Hai Yan Bao ◽  
Zhi Yang Zhou
Keyword(s):  
Wall Thickness ◽  
Rolling Process ◽  
Steel Tube ◽  
Transverse Wall ◽  
Data Reliability ◽  
Continuous Rolling ◽  
Roll Speed ◽  
Seamless Steel Tube ◽  
The Relationship ◽  
Seamless Steel

The seamless steel tube continuous rolling process with 8-stand full-floating mandrel is simulated with the aid of commercial FE code MSC. SuperForm. The relationship is analyzed between the distribution of the transverse wall-thickness and the speed schedule of the rollers. The result shows that the transverse evenness of the wall thickness of the tubes can be enhanced by optimizing the speed schedule. Furthermore, by adopting meliorated method to measure the wall-thickness of the shell, the error is reduced while data reliability is increased. When using the existing equipments (mandrel mill), it is an effective way to improve the transverse wall-thickness accuracy of the shell tube by adjusting the speed schedule. Compared with present roll speed schedule, the transverse wall-thickness accuracy can be increased by 10% for the rolling of elongated shell with 152.5mm in OD and 6mm in wall thickness tube under the 3# speed schedule put forward in this paper.

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.

Evaluation of Deformation Characters in Edgesof Hot Rolled Slab by Lode Parameter

2013 ◽  
Vol 668 ◽  
pp. 437-441
Author(s):  
Hong Xia Bian ◽  
Liang Zhu ◽  
Guo Qing Hou
Keyword(s):  
Deformation Zone ◽  
Tensile Deformation ◽  
Metal Flow ◽  
Element Model ◽  
Quantitative Relation ◽  
Stress Strain ◽  
Lode Parameter ◽  
Edge Defects ◽  
Parameter Values ◽  
Rolling Deformation

The hot rolling processes of slabs have been simulated by 3-D explicit dynamics Thermal-mechanical Finite Element Model (FEM) to solve the problems of edge defects. It can analyze the deformation characteristics of rolling slabs, calculate Lode parameter values in rolling deformation zone and analyze the stress-strain state in the entrance and exit of the slabs edge. Because there are the relationship between plastic deformation types and Lode parameter, and the quantitative relation metal flow and various Lode parameter. Results showed that there are complicated metal flow and various Lode parameter values in the edge of rolling deformation zone. Although there stress-strain states are various in the entrance and exit of the slab edges the μdε<0, the tensile strain increment in the direction of max principle strain was bigger than another two directions and the edges had the character of tensile deformation. This is the major cause that edge of slab is more defects than other zone.

Investigation of influence of plate rolling parameters on the product quality

2020 ◽  
Vol 76 (6) ◽  
pp. 591-601
Author(s):  
A. Kawalek ◽  
H. Dyja ◽  
K. Ozhmegov
Keyword(s):  
Numerical Simulation ◽  
Hot Rolling ◽  
Deformation Zone ◽  
Rolling Mill ◽  
Metal Flow ◽  
Rolling Process ◽  
Asymmetric Rolling ◽  
Auxiliary Equipment ◽  
Plate Rolling ◽  
Work Rolls

During plate rolling in most cases a breakdown of symmetry conditions of the strip deformation relative to the upper and lower rolls takes place. The rolling process becomes an asymmetric one. This phenomenon causes an adverse bending of the strip towards the lower or upper roll. Subsequent finishing operations do not ensure the exclusion of the deformed (wavy) shape, since the strip has a high rigidity. With this production, large technological waste, associated with the undulation of the front end of the strip arises. In addition, the work rolls of the rolling mill and auxiliary equipment are subject to increased wear. The introduction of controlled asymmetry into the rolling process by differentiating speed of rotation of the work rolls can be one of the ways to prevent this phenomenon. Using of asymmetry allows to change the stress and strain state in the deformation zone. This method does not increase the load on the rolling stand and the gear of the rolling mill. The paper presents results of investigation of plate rolling parameters (billet feeding angle, degree of deformation, value of the asymmetry coefficient of rolls rotation speed) on the strip curvature. The work was carried out according to conditions of hot rolling of steel grade S355J2+N. For numerical simulation of the rolling process the coefficients of the Hensel–Spittel function were refined. The authors conducted a study of rolling of plates using two types of asymmetry, a geometric (as a result of feeding the workpiece at an angle) and a kinetic (by changing the speed of rotation of individual rolls). The analysis of the results was carried out using numerical simulation based on the modern Forge soft- ware package. According to the results of the work, an analysis of the influence of the parameters of plates hot rolling on the metal flow in the deformation zone is presented. The conditions for reducing the curvature of the end of the strip are determined. The expediency of introducing a controlled asymmetric rolling process by application of different speeds of rotation of the work rolls is shown.

Analysis of Transverse Wall Thickness Precision of Steel Tube Rolled by Semi-Floating Mandrel Mill

2010 ◽  
Vol 97-101 ◽  
pp. 3097-3103 ◽  
Author(s):  
Yuan De Yin ◽  
Sheng Zhi Li ◽  
Jie Xu ◽  
Yang Hua Li ◽  
Gong Ming Long ◽  
...  
Keyword(s):  
Wall Thickness ◽  
Rolling Process ◽  
Steel Tube ◽  
Distribution Characteristic ◽  
Transverse Wall ◽  
Analysis Software ◽  
Continuous Rolling ◽  
Boiler Steel ◽  
Element Analysis ◽  
Simulation Results

With the aid of commercial finite element analysis software MSC. Superform, the high pressure boiler steel tube continuous rolling process with 6-stand semi-floating mandrel is simulated, and the distribution characteristic of transverse wall thickness is analyzed. It indicates that it presents “M” shape that the distribution of transverse wall thickness of hollow tube along one-fourth groove periphery. Transverse wall thicknesses have low values at the top, the bottom and sidewall 45 degree or so of groove, and they have high values at the sidewall 23 degree and 67 degree or so of groove. Then the improved measure is put forward on the basis of analyzing the causes responsible for transverse wall thickness. By the comparison of the simulation results, they have been improved obviously that transverse wall thickness precision and real roundness of rolled hollow tube using the improved measure.

The Influence of Rolling Parameters on Metal Flow Law of H-Beam

2014 ◽  
Vol 898 ◽  
pp. 201-204
Author(s):  
Jin Hong Ma ◽  
Xiao Han Yao ◽  
Bin Tao
Keyword(s):  
Metal Flow ◽  
Rolling Process ◽  
Fe Model ◽  
Continuous Rolling ◽  
Elongation Ratio ◽  
Deformation Law ◽  
Hot Continuous Rolling ◽  
Flow Law ◽  
H Beam ◽  
Deform 3D

According to the production data of a rolling H-beam factory, the FE model of hot continuous rolling process of H-beam is built. With the FEM software of DEFORM-3D, the continuous rolling of H-beam was simulated. On base of simulation result, the metal flow and deformation law are discussed. Because of the flange and web is deformed in the different deformation zone, the metal flow law of flange and web is complex, especially the metal of the conjunction of flange and web. The exchange of metal between the flange and the web of H-beam alters to the different elongation ratio of flange and web. The other factors which influents on the metal flow , are taken into consideration, such as rolling speed and friction coefficient. By adjustment to the rolling parameters, the defect of the H-beam is reduced.

A Numerical Simulation of Hot Rolling Process of H-Beams

2012 ◽  
Vol 263-266 ◽  
pp. 670-673
Author(s):  
Wen Ping Liu ◽  
Pei Qi Wang
Keyword(s):  
Hot Rolling ◽  
Metal Flow ◽  
Fem Simulation ◽  
Coupling Model ◽  
Rolling Process ◽  
Three Dimension ◽  
Continuous Rolling ◽  
Mechanical Coupling ◽  
Hot Rolling Process ◽  
Rolling Torque

To estimate the effect of roller deformation on the workpiece during the rolling process of H-beams, it is essential to consider the force exerted on the rollers and the deformation thereof. For this purpose, a three-dimension thermo-mechanical coupling model has been built with the finite element analytical package ABAQUS to simulate the hot rolling process of H-beams. In particular, the simulation is conducted under the assumption that the rollers are elastic and rolling torque imposed unilaterally, which agrees with the practical rolling conditions. Noting the results of FEM simulation, the metal flow and temperature distribution have been obtained. To verify the effectiveness of the proposed simulation, comparisons of the roller contact reaction and temperature between the simulated and measured values have been made. The simulation is meaningful for preparing continuous rolling procedures of H-beams.

Sign in / Sign up

Export Citation Format

Share Document