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Research Papers

A New Model for the Prediction of Roll Deformation in a 20-High Sendzimir Mill

[+] Author and Article Information
S. M. Hwang

e-mail: smhwang@postech.ac.kr
Department of Mechanical Engineering,
Pohang University of Science and Technology,
Pohang 790-784, Korea

1Corresponding author.

Manuscript received June 27, 2012; final manuscript received September 11, 2013; published online November 5, 2013. Assoc. Editor: Jyhwen Wang.

J. Manuf. Sci. Eng 136(1), 011004 (Nov 05, 2013) (12 pages) Paper No: MANU-12-1192; doi: 10.1115/1.4025453 History: Received June 27, 2012; Revised September 11, 2013

A sound model for the prediction of the deformed roll profile during flat rolling is vital for the precision control of the strip profile and strip shape. However, preliminary investigations reveal that the applicability of existing models may be limited due to their inherent predictions errors. In this paper, a new model is proposed which is capable of precisely predicting the deformed roll profile in a multihigh mill. The model, which is developed on the basis of the predictions from finite element simulation, is applied to the analysis of roll deformation in a 20-high Sendzimir mill under some special conditions, such as rigid outer rolls and no roll shifting, etc. The prediction accuracy of the new model is demonstrated through comparison with the predictions from the finite element simulation.

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Figures

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Fig. 1

A sketch describing a 20-High Sendzimir Mill

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Fig. 2

The roll geometry used for the prediction of the deformed roll profile

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Fig. 3

The force profile acting at the work roll-strip interface. type 1 = an edge wave type, type 2 = flat type, and type 3 = center buckle type.

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Fig. 4

Meshes used for FE simulation. The meshes were selected after performing a series of convergence tests, in order to remove the mesh dependency of the solution.

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Fig. 5

Deflection of the work roll, predicted from the slit beam model and from FEM. The prediction errors of the slit beam model at the end of the roll barrel are, 12.5% for type 1, 11.5% for type 2, and 11.5% for type 3.

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Fig. 6

Roll flattening at the work roll-strip interface, predicted from Tozawa's model and from FEM.

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Fig. 7

Two kinds of forces acting on a roll. Pr(x) is generated by roll-to-roll contact, and Ps(x) is generated by roll-to-strip contact.

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Fig. 8

Decomposition of Ps(x)

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Fig. 9

Deformed roll profile y(x) at the bottom of a roll due to force profile Pr(x) or Ps(x) acting at the bottom of the roll. Note that in Fig. 11, y(x) represents Δuy(θ = 0,x).

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Fig. 10

The cross sectional view of the deformed roll. The force profile is Pr(x), acting at the bottom (θ = 0) of the roll.

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Fig. 11

Distribution of Δuy(θ,x) along the circumferential direction. The force profile is Pr(x), acting at the bottom (θ = 0) of the roll, as shown in Fig. 9. D = 88 mm, L/2 = 1000 mm, x = 800 mm

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Fig. 12

Distribution of Δuz(θ,x) along the circumferential direction. The force profile is Pr(x), acting at the bottom (θ = 0) of the roll, as shown in Fig. 9. D = 88 mm,L/2 = 1000 mm,x = 800 mm

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Fig. 13

Distribution of Δuy(θ,x) along the circumferential direction. The force profile is Ps(x), acting at the bottom of the roll, 0 < θ < ϕ, where ϕ is the bite angle.

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Fig. 14

Distribution of Δuz(θ,x) along the circumferential direction. The force profile is Ps(x), acting at the bottom of the roll, 0< θ < ϕ, where ϕ is the bite angle.

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Fig. 15

Roll numbers, interface numbers, and the definition of angles used in the calculation

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Fig. 16

The mesh used for FE simulation of the elastic deformation of the rolls in a 20-high Sendzimir mill

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Fig. 17

Radial displacement of the 2nd intermediate roll (R4), at the cross-section 900 mm apart from the center of the roll, predictions from the model and from FE simulation. The angle is measured counterclockwise from the bottom of the roll.

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Fig. 18

Force profile acting at the interface between 2nd intermediate roll (R4)—backup roll (R7), predicted from the model and from FEM

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Fig. 19

Force profile acting at the interface between 1st intermediate roll (R2)—2nd intermediate roll (R4), predicted from the model and from FEM.

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Fig. 20

Radial displacement of the 1st intermediate roll (R2), at the cross-section 900 mm apart from the center of the roll, predictions from the model and from FE simulation. The angle is measured counterclockwise from the bottom of the roll.

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Fig. 21

Force profile acting at the interface between 1st intermediate roll (R2)—2nd intermediate roll (R5), predicted from the model and from FEM

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Fig. 22

Force profile acting at the interface between the work roll (R1)—1st intermediate roll (R2), predicted from the model and from FEM.

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Fig. 23

Radial displacement of the work roll (R1), at the cross-section 900 mm apart from the center of the roll, predictions from the model and from FE simulation. The angle is measured counterclockwise from the bottom of the roll.

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Fig. 24

Deformed roll profile at the bottom of the work roll, Predictions from the present model and FE simulation. Roll barrel length = 2000 mm, strip width = 1800 mm, roll force = 2.0 kN/mm, uniformly distributed.

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