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Research Papers

Finite Element Analysis on Chattering in Cold Rolling and Comparison With Experimental Results

[+] Author and Article Information
Reza Mehrabi

Department of Mechanical Engineering,
Vali-e-Asr University of Rafsanjan,
Rafsanjan 77139-36417, Iran
e-mail: r.mehrabi@vru.ac.ir

Mahmoud Salimi

Department of Mechanical Engineering,
Isfahan University of Technology,
Isfahan 84156-83111, Iran
e-mail: salimi@cc.iut.ac.ir

Saeed Ziaei-Rad

Department of Mechanical Engineering,
Isfahan University of Technology,
Isfahan 84156-83111, Iran
e-mail: szrad@cc.iut.ac.ir

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received January 9, 2015; final manuscript received April 3, 2015; published online September 9, 2015. Assoc. Editor: Tony Schmitz.

J. Manuf. Sci. Eng 137(6), 061013 (Sep 09, 2015) (9 pages) Paper No: MANU-15-1018; doi: 10.1115/1.4030379 History: Received January 09, 2015

In this paper, the chattering phenomenon in cold rolling is investigated in reference to the finite element method (FEM). The structure of the mill stand is modeled as a system of linear springs and lumped masses while the rolling process is modeled utilizing an implicit FEM. Assembling the two models makes it possible to detect the chatter during the rolling process. The assembled model is capable of perceiving variations in forces generated during the process that deflects the structure of the mill leading to variations at the roll gap and the roll speed. The influences of some rolling parameters on chatter vibration are investigated. Predicted values of the model are in good agreement with that of the experiments as well as the values obtained by other researchers.

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References

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Figures

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Fig. 1

Representation of chatter as a closed loop [2]

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Fig. 2

Multimodal structural model [3]

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Fig. 3

The FE model of stand for chatter simulation [19]

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Fig. 4

(a) The appropriate mesh for the sheet and (b) the meshing technique for the work roll

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Fig. 5

Proposed dynamic model for explanation of the chatter phenomenon as the result of transformation of the plate: (a) without effect of resistance force and (b) with effect of resistance force

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Fig. 6

Calculated rolling force using FE model

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Fig. 7

(a) The reaction force of the work roll versus time and (b) the displacement of the work roll versus time (rolling speed = 6 m/s)

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Fig. 8

(a) The displacement of the work roll versus time and (b) frequency response of the work roll signal to the impulse excitation (rolling speed = 12 m/s)

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Fig. 9

(a) The displacement of the work roll versus time and (b) frequency response of the work roll signal to the impulse excitation (rolling speed = 17 m/s)

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Fig. 10

The displacement of the work roll versus time (rolling speed = 22 m/s)

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Fig. 11

The comparative displacement between work roll and backup roll versus time (sheet velocity = 17 m/s)

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Fig. 12

The effect of friction coefficient on the stability of the rolling system: (a) present model, (b) experimental result [7], and (c) study of friction coefficients on stability in different reductions

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Fig. 13

The effect of reduction on the stability of the system

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Fig. 14

The effect of sheet thickness on the stability of the system

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Fig. 15

(a) Chatter-marked cold-rolled sheet product and (b) possible strip defect due to rolling mill vibration

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Fig. 16

Chatter marks on backup rolls of the sheet mill in the Esfahan Mobarakeh Steel Complex (EMSCo.)

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