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research-article

A Roll-Stack Contact Mechanics Model to Predict Strip Profile in Rolling Mills with Asymmetric CVC Roll Crowns

[+] Author and Article Information
Feng Zhang

Mechanical Engineering Department, Eric Jonsson School of Engineering and Computer Science, The University of Texas at Dallas, 800 W. Campbell Rd., Richardson, TX 75080, USA
feng.zhang@utdallas.edu

Arif S Malik

ASME Member, Mechanical Engineering Department, Eric Jonsson School of Engineering and Computer Science, The University of Texas at Dallas, 800 W. Campbell Rd., Richardson, TX 75080, USA
arif.malik@utdallas.edu

1Corresponding author.

ASME doi:10.1115/1.4037600 History: Received December 29, 2016; Revised July 31, 2017

Abstract

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 method to consider complex antisymmetric contact conditions of continuously variable crown (CVC) roll diameter profiles designed for use with work-roll shifting on 4-high mills, and intermediate-roll shifting on 6-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 continuously variable crown 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 finite element simulations for a 4-high mill with work-roll CVC shifting, and a thin-strip 6-high mill with intermediate-roll CVC shifting.

Copyright (c) 2017 by ASME
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