Analysis of 3D Plastic Deformation in Vertical Rolling Based on Global Weighted Velocity Field

Energy method is an essential theoretical approach to analyze plastic forming, which is widely used in rolling. An analysis model for vertical rolling process is established according to energy theory. By using global weighted method firstly, the 3D continuous velocity field, strain rate field and the corresponding power functional are proposed. The unknown variables are solved numerically based on the principle of minimum energy. Then, deformation parameters and rolling force are determined. The analysis on specific examples with the width reduction rate of 0.03~0.05 shows that the theoretical prediction value of weighted model is in good agreement with experimental results. Moreover, the effects of several shape and rolling parameters on rolling force, rolling power and edge deformation are studied. Both the width reduction rate and initial slab thickness have significant influences on dog-bone size and rolling force. A wider slab slightly increases the nonuniformity of dog-bone deformation. An increase of vertical roller radius can weaken the edge deformation.

A Fault Diagnosis Method of Rolling Mill Bearing at Low Frequency and Overload Condition Based on Integration of EEMD and GA-DBN

To solve the problems of difficult fault signal recognition and poor diagnosis effect of different damage in the same position in rolling mill bearing at low speed, a fault diagnosis method of rolling mill bearing based on integration of EEMD and DBN was proposed. The vibration signals in horizontal, axial, and vertical directions were decomposed and reconstructed by EEMD, and frequency domain analysis was carried out by using refined spectrum. Then, the signal's time-frequency domain index, rolling force, and torque component feature vector were input into genetic algorithm (GA) to optimize DBN model classification. In order to verify the effectiveness of the method, the experimental study was carried out on the two-high experimental rolling mill. The results show that EEMD combined with thinning spectrum can solve the problem of fault feature extraction well. Compared with time-frequency domain characteristic input, the prediction accuracy of DBN model is obviously improved. And the accuracy of GA-DBN model is higher, and the accuracy is 98.3%, and the time taken to diagnose is significantly reduced. Finally, the fault classification of different parts of bearings and the fault diagnosis of different damage in the same part are realized, which provides a good theoretical basis for the fault diagnosis of low-speed bearings and has important engineering significance.

Accurate Strain Field Measurement During Strip Rolling by Exploiting Recurring Material Motion with Time-Integrated Digital Image Correlation

Background 95% Of all metals and alloys are processed using strip rolling, explaining the great number of existing strip rolling optimization models. Yet, an accurate in-situ full-field experimental measurement method of the deformation, velocity and strain fields of the strip in the deformation zone is lacking. Objective Here, a novel time-Integrated Digital Image Correlation (t-IDIC) framework is proposed and validated that fully exploits the notion of continuous, recurring material motion during strip rolling. Methods High strain accuracy and robustness against unavoidable light reflections and missing speckles is achieved by simultaneously correlating many (e.g. 200) image pairs in a single optimization step, i.e. each image pair is correlated with the same average global displacement field but is multiplied by a unique velocity corrector to account for differences in material velocity between image pairs. Results Demonstration on two different strip rolling experiments revealed previously inaccessible subtle changes in the deformation and strain fields due to minor variations in pre-deformation, elastic recovery, and geometrical irregularities. The influence of the work roll force and entry/exit strip tension has been investigated for strip rolling with an industrial pilot mill, which revealed unexpected non-horizontal material feed. This asymmetry was reduced by increasing the entry strip tension and rolling force, resulting in a more symmetric strain distribution, while increased distance between the neutral and entry point was found for a larger rolling force. Conclusions The proposed t-IDIC method allows for robust and accurate characterization of the strip’s full-field behavior of the deformation zone during rolling, revealing novel insights in the material behavior.

A simplified mathematical model for total temperature rise calculation in non-oriented silicon steel cold rolling deformation zone

In tandem cold rolling, the control of the temperature of high-grade non-oriented silicon steel is a difficult problem for its large deformation resistance and the preheating procedure before rolling. And it is complicated to calculate the total temperature rise of rolling deformation zone due to the comprehensive influence of the plastic deformation heat, the friction heat and the contact heat loss. So, to precisely calculate the total temperature rise, firstly, based on the four classical cold rolling force formulas, the initial total temperature rise calculation models are established correspondingly by theoretically analyzing the temperature rise of deformation heat, the temperature rise of friction heat and the temperature drop of contact heat loss; then, the model based on the improved Lian rolling force formula is adopted, which leads to calculated best matching the measured temperature; finally, considering the complex formula calculation of the initial model, based on the influences of different rolling parameters on the total temperature rise, a simplified model for convenient calculation is proposed by the nonlinear regression analysis of the initial model calculation results and main rolling parameters, which is convenient for the actual application by the field technicians.

Profile Design of the Grooved Die and Rolling Force Prediction in the Cold Pilger Rolling Process

The objective of this study was to design the die groove profile and predict the rolling force produced when employing the variable curvature rolls and mandrel for manufacturing seamless pipes using the cold pilger rolling process. The parameters of the key process design were the diameter of the initial tube and final product, as well as the feed amount, reduction area, principal deformation zone, and roller radius. The rolling forces during the pilger rolling process were theoretically calculated to enable their prediction, and the characteristics of the cold pilger rolling process were identified. The calculated values were in close agreement with the experimental data. The die groove design is important in the prediction process because the dimensional accuracy of the tubes and the life of the dies are highly dependent on this design. The presented design method can be successfully applied to fulfill this objective. The tube shape and adequate tolerance can be attained by using the proposed design method. The mechanical properties of the pipe are evaluated by calculating the Q factor.

Modelling of Deformation Resistance with Big Data and Its Application in the Prediction of Rolling Force of Thick Plate

The precision of traditional deformation resistance model is limited, which leads to the inaccuracy of the existing rolling force model. In this paper, the back propagation (BP) neural network model was established according to the industrial big data to accurately predict the deformation resistance. Then, a new rolling force model was established by using the BP neural network model. During the establishment of the neural network model, the data set of deformation resistance was established, which was calculated back from the actual rolling force data. Based on the data set after normalization, the BP neural network model of deformation resistance was established through the optimization of algorithm and network structure. It is shown that both the prediction accuracy of the neural network model on the training set and the test set are high, indicating that the generalization ability of the model is strong. The neural network model of the deformation resistance is compared with the theoretical one, and the maximum error is only 3.96%. Furthermore, by comparison with the traditional rolling force model, it is found that the prediction accuracy of the rolling force model imbedding with the present neural network model is improved obviously. The maximum error of the present rolling force model is just 3.86%. The research in this paper provides a new way to improve the prediction accuracy of rolling force model.

A New Method of Manufacturing Hollow Shafts via Flexible Skew Rolling

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.

Formability Difference between TC4 Titanium Alloy Hollow Shaft and AISI 1045 Steel Hollow Shaft Formed by Cross Wedge Rolling with a Mandrel

Production of TC4 alloy hollow shaft formed by cross wedge rolling (CWR) can meet the needs of the lightweight structures in aviation field. Different from the steel, the formability of TC4 alloy is sensitive to deformation temperature. In this work, the formability difference of TC4 alloy hollow shaft and AISI 1045 steel hollow shaft formed by CWR with a mandrel was studied numerically and experimentally. The results show that the influence of temperature on TC4 alloy flow stress is larger than that of 1045 steel, and the peak stress of TC4 alloy at 900 °C is close to that of 1045 steel at 1050 °C. For the hollow shafts of two materials, the ellipticity increases with increasing the inner hole diameter. For the same size of thin-walled billets, the forming quality of TC4 alloy at 900 °C is better than that of 1045 steel at 1050 °C. The CWR temperature range of TC4 alloy is narrower than 1045 steel. The increase of the initial deformation temperature can significantly increase the ellipticity of TC4 alloy and the appropriate forming temperature range of CWR TC4 alloy hollow shaft should be lower than 950 °C. Moreover, the rolling force and torque of TC4 alloy hollow shaft are smaller than that of 1045 steel when CWR hollow billet with the same dimensions.