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Research Papers

A Roll-Stack Contact Mechanics Model to Predict Strip Profile in Rolling Mills With Asymmetric, Continuously Variable Crown Rolls

[+] Author and Article Information
Feng Zhang

Mem. ASME
Mechanical Engineering Department,
Eric Jonsson School of Engineering
and Computer Science,
The University of Texas at Dallas,
800 West Campbell Road,
Richardson, TX 75080
e-mail: feng.zhang@utdallas.edu

Arif Malik

Mem. ASME
Mechanical Engineering Department,
Eric Jonsson School of Engineering
and Computer Science,
The University of Texas at Dallas,
800 West Campbell Road,
Richardson, TX 75080
e-mail: arif.malik@utdallas.edu

1Corresponding author.

Manuscript received December 29, 2016; final manuscript received July 31, 2017; published online November 16, 2017. Assoc. Editor: Yannis Korkolis.

J. Manuf. Sci. Eng 140(1), 011008 (Nov 16, 2017) (15 pages) Paper No: MANU-16-1685; doi: 10.1115/1.4037600 History: Received December 29, 2016; Revised July 31, 2017

Introduced is an efficient new model to compute the roll-stack deflections and contact mechanics behaviors for metal rolling mills with asymmetric roll crowns. The new model expands the simplified mixed finite element (FE) method to consider complex antisymmetric contact conditions of continuously variable crown (CVC) roll diameter profiles designed for use with work-roll (WR) shifting on four-high mills, and intermediate-roll (IR) shifting on six-high mills. Conventional roll-stack deflection models are either more computationally expensive or exploit more simplifying assumptions. Moreover, almost all existing approaches fail to adequately simulate the antisymmetric CVC contact problem required for model-based control of thickness profile and flatness in hot and cold CVC rolling mills. The presented model efficiently captures bending, shear, and flattening deformations while computing contact interference forces, binary contact locations, and net effects of roll and strip crowns. Strip thickness profiles and contact force distributions predicted by the new model are checked against known theoretical solutions, and compared to predictions from large-scale FE simulations for a four-high mill with WR CVC shifting, and a thin-strip six-high mill with IR CVC shifting.

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Figures

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Fig. 1

Four-high rolling mill equipped with WR CVC shifting: (a) side view, (b) front view, and (c)(e) strip profile and contact force distribution effects for CVC WR shifting directions (note CVC profile on WRs are highly exaggerated)

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Fig. 2

Flowchart of the CVC roll-stack model indicating roll profile contact algorithm

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Fig. 3

“Classic” and “advanced” types of CVC diameter profiles in standard industrial practice (exaggerated for illustration purposes)

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Fig. 4

Theoretical examples for a two-high mill with uniform WR gap profiles

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Fig. 5

Contact interference for cases A, B, and C in Fig. 4 using recalculated strip center line

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Fig. 6

Contact force distribution for cases A, B, and C in Fig. 4 using recalculated strip center line

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Fig. 7

Contact force distribution for cases B and C in Fig. 4 without recalculated strip center line

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Fig. 8

Large-scale FE model of four-high WR CVC mill (ABAQUS® 6.14 using 1.858 M linear hexahedron elements)

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Fig. 9

Comparison of thickness strain distribution predictions for new model and large-scale FE model; four-high mill with CVC profile on WR (no shifting)

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Fig. 10

Comparison of percent difference in strain prediction for new model relative to large-scale FE model; four-high mill with CVC profile on WR (no shifting)

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Fig. 11

Comparison of predictions for vertical displacement of roll axes with new model and large-scale FE model; four-high mill with CVC profile on WR (no shifting). Predictions given for top and bottom WR and BUR.

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Fig. 12

Comparisons of CVC shifting effects on thickness strain for FE model (left) and new model (right) on four-high mill with CVC profile on WR (value for each curve indicates shifting of top WR, as illustrated in Figs. 1(d) and 1(e))

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Fig. 13

Comparison of percent difference in strain prediction under CVC shifting for new model relative to large-scale FE model; four-high mill with CVC profile on WR

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Fig. 14

Binary contact nonlinearity predictions based on contact force distributions for FE model (top) and new model (bottom) without CVC shifting. Note asymmetry of lost contact locations on WR/BUR interfaces due to CVC WR profile (from Eq. (9b)) and mill loading.

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Fig. 15

Comparisons of predicted and measured CVC shifting effects on thickness strain for six-high mill with machined CVC profile on intermediate rolls

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Fig. 16

Schematic of typical six-high CVC mill with IRS, WRB, and IRB. Displacement (screw down) and fixed boundary conditions on BUR necks are also shown.

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Fig. 17

Case study results of strip thickness profile (left) and thickness strain (right)

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Fig. 18

Case study results of vertical displacement (left) and contact force distribution (right)

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Fig. 19

Strip cross-sectional thickness profile parameter definitions

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