Analysis of elastic rolling stand deformation and interstand tension effects on section faults of hot rolled wire rod and bars

Overhagen, Christian; Braun, Rolf; Deike, Rüdiger

doi:10.1515/teme-2019-0130

Cited by 5 publications

(3 citation statements)

References 2 publications

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“…Besides the approach of tracing the groove rolling back to an equivalent flat rolling pass, there were also investigations focusing on the modelling of material flow, including the actual shape of the groove (Goldhahn, 1981;Hensel & Goldhahn, 1981;Hensel & Spittel, 1978;Kopp et al, 1985;Mauk & Kopp, 1982). To make optimum use of these models, attempts to automatic groove pass design were always an issue of development (Betshammer, 2006;Eriksson, 2004Eriksson, , 2005Eriksson & Lundberg, 2004;Hensel, 1987;Hensel & Großmann, 1987;Hensel & Wehage, 1988;Körmer, 1987;Krause et al, 2007;Kunzman, 1977;Lambiase & Langella, 2009;Malmgren, 2000;Ogoltcov et al, 2015;Overhagen, Braun, Gamal, et al, 2020;Overhagen, Braun, & Deike, 2020;Overhagen, 2021;Schmidt, 1997;Schmidtchen et al, 2020;Schmidtchen & Prahl, 2021). An exhaustive overview of general tasks in roll pass design and published models is given by Oduguwa & Roy (2006).…”

Section: Statement Of Needmentioning

confidence: 99%

PyRolL - An Extensible OpenSource Framework for Rolling Simulation

Weiner,

Renzing,

Stirl

et al. 2024

JOSS

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Groove rolling is one of the main process routes for the production of metal long products, such as bars, beams, wires, and rods. In this process, a workpiece is deformed by two or more rotating rolls to reduce the cross-section to achieve a desired cross-section shape. The shape is determined by the contour of the rolls' surfaces, called the groove or calibre. The process is usually accomplished in multiple steps, each called a pass. The industry is currently under heavy pressure to optimize its processes regarding energy consumption while maintaining or increasing product quality. The introduction of new materials and alloys challenges production and technology engineers. In the past decades, numerical simulation tools have become an integral part of process development and maintenance. They are used to estimate forces and engine torques, as well as geometrical and microstructural evolution of the workpiece for a given pass sequence and input workpiece geometry and material. This knowledge is important to design or optimize a process, identify sources of errors, increase product quality or extend the product portfolio.PyRolL is an open-source, modular, and extensible framework aiming at the numerical simulation of groove rolling processes and accompanying processes, such as heating, cooling, and transportation. PyRolL Core serves as the basis for model and application development by defining needed data structures and solution algorithms and providing a versatile plugin system. Rolling processes are quite a complex issue since a simulation has to regard the mechanical behavior of the workpiece and plant, as well as thermodynamic and chemical processes occurring within the workpiece. The plugin system enables a modular simulation setup, where the user can choose from a growing library of state-of-the-art model approaches published in scientific literature that target specific aspects of the process such as material flow, stress state, thermal evolution, microstructure evolution or elastic tool response. Additional and new model approaches can be implemented as plugin packages and used just the same as officially provided ones. By this concept, the ecosystem can grow and thus avoid the need to implement the basics every time, so the user or developer can concentrate on the actual focus of their work.

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Section: Statement Of Needmentioning

confidence: 99%

PyRolL - An Extensible OpenSource Framework for Rolling Simulation

Weiner,

Renzing,

Stirl

et al. 2024

JOSS

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“…The idea covered in this paper is to construct a data-driven model for pass design based upon analytical pass design computations carried out by a deterministic pass design model which was developed at the Chair of Metallurgy and Metal Forming of the University of Duisburg-Essen [8,9]. In order to allow the digitization of groove geometries, these were reduced to a set of few simple geometric parameters.…”

Section: Introductionmentioning

confidence: 99%

Data-Driven Roll Pass Design of Wire Rod Mills

Overhagen

2022

KEM

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The classical approach for roll pass design of a wire rod mill employs an iterative technique incorporating spread calculation and rectangular equivalent pass methods. This method comes to its limits in terms of computational efficiency and numerical stability when a complete pass design for a wire rod mill with lots of different final dimensions and materials must be designed. To improve the pass design technique, a fast data-driven method for pass design based on synthetic data generated by the classical pass design model was created. The results are compared to the original training data, as well as newly generated test data. It is shown that the artificial neural network (ANN) is able to predict appropriate oval groove geometries with good precision.

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“…Introduced to the market a few years ago, the four-roll rolling process (4RP) is a new method for sizing of round sections to minimize cross-sectional variations which occur during hot rolling due to the elastic mill behavior and interstand tensions in continuous rolling mills [1]. The elongation efficiency in the 4RP is expected to be even better than in the well-established three-roll rolling process (3RP) [2].…”

Section: Intr Introduction Oductionmentioning

confidence: 99%

A computational method for pass design of the four-roll rolling process for sizing of round sections

Overhagen¹

2021

Esaform 2021

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The four-roll rolling process (4RP) enables the further evolution of sizing processes in rolling mills for round sections. The well-known advantages of the three-roll process over the two-roll process can be further improved using the 4RP. The participation of four rolls in the deformation zone instead of three or two leads to a significant increase in deformation efficiency. The present work shows a pass design method for pass sequences in the four-roll rolling process. Here, three basic types of roll groove geometries are discussed: the flat groove, the non-opened single-radius groove, and a tangentially opened type of a single radius groove. Based on a predefined cross-sectional evolution, grooves are found numerically to satisfy two conditions, i.e., the cross section of the rolled section and the groove filling criterion. The equations of the equivalent pass method, together with a suitable model for lateral spread and the geometric equations of the groove are solved by nonlinear optimization to minimize the sectional and filling errors of a specific pass. Combined for several rolling passes, a complete pass design can be carried out for the reduction of a specified initial section to a final section. The presented results show, how a pass design method for the four-roll rolling process can be constructed. The newly developed model is implemented in a software solution for pass design and analysis of full section rolling mills. An exemplified pass design is discussed to show the possibilities and limitations of the new model.

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Analysis of elastic rolling stand deformation and interstand tension effects on section faults of hot rolled wire rod and bars

Cited by 5 publications

References 2 publications

PyRolL - An Extensible OpenSource Framework for Rolling Simulation

PyRolL - An Extensible OpenSource Framework for Rolling Simulation

Data-Driven Roll Pass Design of Wire Rod Mills

A computational method for pass design of the four-roll rolling process for sizing of round sections

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