Influence of work-roll grinding error and high-fidelity corrective grinding in cold sheet rolling
Influence of work-roll grinding error and high-fidelity corrective grinding in cold sheet rolling
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DOI：
10.1007/s00170-022-09228-7
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发表时间：
2022-02
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影响因子：
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通讯作者：
Akash M. Patel;A. Malik;Fengke Zhang;Ritin Mathews
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文献类型：
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作者：
Akash M. Patel;A. Malik;Fengke Zhang;Ritin Mathews
冷轧带钢和冷轧薄板的高保真板形缺陷是由高度局部化的厚度应变变化引起的，给金属工业带来了持续的挑战。根据轧制实践，这些缺陷的一个主要原因是由于轧辊磨削误差引起的局部工作辊直径偏差的转移，但其影响尚未得到严格的调查。研究了不锈钢、铝、铜冷轧过程中工作辊直径偏差的高保真传递问题。在四辊轧机上进行了参数研究，考察了轧辊直径、压下率、带钢宽度和材料对高保真工作辊直径偏差传递的影响。研究使用了一种有效的三维辊叠模型，该模型通过简化-混合有限元方法预测带钢厚度分布偏差。量化和分析了与板形缺陷有关的带钢出带压下偏差，以了解工作辊磨削偏差相对于完全磨削(光滑)工作辊的传递特性。结果表明，高保真传递不仅与轧辊磨削偏差幅度和轧辊载荷有关，还与轧辊三维整体变形引起的轧辊辊面长度偏差的具体位置以及工作辊与带钢的有效刚度比有关。总结这项研究是一种识别定制工作辊磨削轮廓的新方法，该定制工作辊磨削轮廓是专门为消除先前存在的高保真带材平坦度缺陷模式而定制的，其中“校正”的高保真轧辊直径轮廓解释了预测的3D轧机变形、接触力分布和耦合的微观/宏观尺度变形力学。
High-fidelity flatness defects in cold-rolled strip and sheet, arising from highly localized thickness strain variations, present an ongoing challenge to the metal industry. A primary cause of such defects, based on rolling practice, but for which the effects have not been rigorously investigated, is the transfer of localized work-roll diameter deviations due to roll grinding error. This study addresses high-fidelity work-roll diameter deviation transfer in the cold rolling of stainless steel, aluminum, and copper. Parametric studies are performed on a 4-high mill to examine the influences of roll diameter, reduction, strip width, and material on the transfer of high-fidelity work roll diameter deviations. Studies are conducted using an efficient 3D roll-stack model that predicts strip thickness profile deviations via the simplified-mixed finite element method. Reduction deviations on the outgoing strip, which correlate to strip flatness/shape defects, are quantified and analyzed to understand the transfer characteristics of work-roll grinding deviations relative to perfectly ground (smooth) work rolls. The results reveal that high-fidelity transfer depends not only on roll grinding deviation amplitudes and mill loading, but also on the specific locations of deviations along the roll face length due to 3D bulk roll-stack deformations as well as effective stiffness ratio between the work roll and the strip. Concluding the study is a novel approach to identify customized work roll grinding profiles tailored specifically to eliminate pre-existing high-fidelity strip flatness defect patterns, wherein “corrective” high-fidelity roll diameter profiles account for the predicted 3D mill deflections, contact force distributions, and coupled micro-/macro-scale deformation mechanics.