Optimization of groove configurations

Billet of square or rectangular cross section is rolled in grooves on bar mills. The degree of reduction and the shape of the grooves determine the stress state of the metal in the deformation region and the energy consumption in rolling. The tensile stress at the bar surface depends on the longitudinal and transverse deformation. Under the action of the tensile stress, the integrity of the metal surface may be disrupted. For each steel, there is a limiting strain beyond which the bar surface disintegrates. The ratio of the current strain to its limiting value determines the degree to which the metal’s reserve of plasticity has been depleted; that, in turn, characterizes the probability of defect formation at the metal surface. The optimal groove configuration may be selected by simulation of the rolling conditions and assessment of the metal’s plasticity and the energy consumption.     

轧制边线形成过程的有限元分析

利用有限元软件对空冷后具有一定温度梯度的板坯的轧制过程进行数值模拟计算,研究分析两种不同高温力学特性的钢种在轧制时边角部金属的位移、应变及应力情况,分析边部线状缺陷起源的褶皱的形成过程并通过轧制试验予以验证。分析结果表明,边线形成与变形温度范围内变形抗力的不连续变化具有明显相关性,变形抗力随温度连续变化的钢种轧制过程角部金属不会形成褶皱;变形抗力随变形温度不连续变化的钢种,当板坯角部金属进入两相区时,由于轧制过程两相区变形抗力出现谷值,易出现褶皱并最终演变为边部线状缺陷。     

热连轧低合金钢边部横裂形成原因分析

通过采集现场过程数据,从温度、成分、相变、晶粒形貌、轧制变形应力等方面对低合金钢Q355B宽规格钢板在热连轧过程中产生边部横向裂纹缺陷的原因进行机理分析。结果表明,宽规格低合金钢边部横向裂纹产生原因与板坯宽度方向温度均匀性相关,边部局部温度过低导致两相区和非再结晶区域轧制,边裂区晶粒度尺寸和形貌与正常区有明显差异,从而导致轧制过程表层和次表层伸长率不一致,高温下局部金属拉伸变形抗力超过抗拉强度,导致了表面横向裂纹缺陷的产生。     

Correlation of microstructure and fracture properties of API X70 pipeline steels

Effects of microstructure on fracture toughness and transition temperature of high-toughness X70 pipeline steels were investigated in this study. Three types of steels were fabricated by varying alloying elements such as C, Cu, and Mo, and their microstructures were varied by rolling conditions such as finish rolling temperature and finish cooling temperature. Charpy V-notch (CVN) impact tests and pressed notch drop-weight tear tests (DWTT) were conducted on the rolled steel specimens. The Charpy impact test results indicated that the specimens rolled in the single-phase region of the steel containing a reduced amount of C and Mo had the highest upper shelf energy (USE) and the lowest energy transition temperature (ETT) because of the appropriate formation of acicular, quasipolygonal, or polygonal ferrite and the decreased fraction of martensite-austenite constituents. Most of the specimens rolled in the single-phase region also showed excellent DWTT properties as the percent shear area (pct SA) well exceeded 85 pct, irrespective of finish cooling temperatures, while their USE was higher than that of the specimens rolled in the two-phase region. Thus, overall fracture properties of the specimens rolled in the single-phase region were better than those of the specimens rolled in the two-phase region, considering both USE and pct SA.     

Behavior of Structural Defects of Already-Deformed Continuous-Cast Bar on Rolling

In the continuous casting of steel ingots, the most significant trend over the last few decades has been the partial transfer of deformation processes from the region of complete solidification (the rolling mill) to the region characterized by a two-phase solid–liquid state (the continuous-casting line). However, such two-stage deformation of the continuous-cast ingot entails changes in the physical modeling of the behavior of surface and interior defects in subsequent rolling. In particular, modifications are required in selecting the geometry and spatial orientation of the defects. In the present work, the influence of the surface-defect orientation and central macrostructure (pore content) of bar billet deformed in the continuous-casting line is investigated by means of laminar physical models. The deformation conditions of reduced-scale (1: 5) continuous- cast billet are studied experimentally in two rolling configurations: (1) the use of smooth rollers to simulate groove-free rolling in the first two stands of the cogging group in the 350 continuous medium-bar mill; (2) rolling in the first and second pairs of straight grooves in the cogging stand of the 500/370 mill at PAO Donetskii Metallurgicheskii Zavod. Since this is a multivariant problem, a universal design has been developed for the physical model, so as to simulate the spatial configuration of both surface and internal defects. The research shows that, in rolling the physical models with an extension coefficient greater than 2.0 and practically 60° inclination of the simulated defects to the rolling axis, their complete elimination is possible. In turn, decreasing the inclination to 30° facilitates greater extension of the simulated defects and only slightly reduces their width. When the inclination of the simulated defects to the rolling axis is 90° (complete lack of coaxiality), broadening of the defects and their compression to the initial length is only observed after 90° rotation. The experimental data provide insights regarding the elimination of internal defects (pores) in the metal as a function of the total extension, the inclination of the defects’ longitudinal axis to the rolling direction, and their distance from the longitudinal–transverse symmetry plane.     

Correlation of microstructure and fracture properties of API X70 pipeline steels

Effects of microstructure on fracture toughness and transition temperature of high-toughness X70 pipeline steels were investigated in this study. Three types of steels were fabricated by varying alloying elements such as C, Cu, and Mo, and their microstructures were varied by rolling conditions such as finish rolling temperature and finish cooling temperature. Charpy V-notch (CVN) impact tests and pressed notch drop-weight tear tests (DWTT) were conducted on the rolled steel specimens. The charpy impact test results indicated that the specimens rolled in the single-phase region of the steel containing a reduced amount of C and Mo had the highest upper shelf energy (USE) and the lowest energy transition temperature (ETT) because of the appropriate formation of acicular, quasipolygonal, or polygonal ferrite and the decreased fraction of martensite-austenite constituents. Most of the specimens rolled in the single-phase region also showed excellent DWTT properties as the percent shear area (pct SA) well exceeded 85 pct, irrespective of finish cooling temperatures, while their USE was higher than that of the specimens rolled in the two-phase region. Thus, overall fracture properties of the specimens rolled in the single-phase region were better than those of the specimens rolled in the two-phase region, considering both USE and pct SA. are jointly appointed with the Materials Science and Engineering Department, Pohang University of Science and Technology.     

精确接触边界条件下热轧带钢轧制力的仿真研究

在流面条元法基础上，将带钢与轧辊的接触面视为三维曲面，结合塑性力学中斜面上应力的求解法，给出了接触表面上的精确应力边界条件，建立了单位轧制压力与变形区内部应力的关系，实现了对板带轧制三维应力和变形的精确分析和计算。热轧带钢轧制力的仿真研究结果表明，新算法(改进算法)的计算精度高于旧算法。     

Numerical simulation of residual stress induced by roll-peening

There are various techniques to improve the components resistance against oscillating loads or fatigue. One of the most efficient techniques is to induce a compressive residual stress layer on the surface of the component. This can be accomplished by different methods such as surface coating, shot-peening, heat treatment, laser peening and roll-peening. The latter is widely used for surface modification of flat and cylindrical industrial components such as crankshaft and etc. The distribution, layer thickness, and the maximum of residual stress induced by roll-peening can be influenced by parameters of rolling such as work piece material, radius of roller curved boundary, roller angular velocity, roller transverse speed, and rolling depth. In this work the effect of these parameters are studied by numerical simulations. The material used in this work is AISI 4340. The roller is a solid disk with a curved boundary. The results indicate that: (i) the surface residual stress increases with the increase of rolling depth up to a specific value thereafter begins to decline; (ii) the effect of roller curvature radius on surface residual stress shows exactly the same trend as the rolling depth does; (iii) for a strain rate hardened material which is the case for the material used in this work, the angular velocity of the roller gives rise to the increase of the surface residual stress and finally, (iv) the increase of the transverse speed of the roller brings about the reduction in the residual surface, as expected.     

Formation Mechanisms of Cracks Formed During Hot Rolling of Free-Machining Steel Billets

In this study, cracks formed in the edge side of Bi-S–based free-machining steel billets during hot rolling were analyzed in detail, and their formation mechanisms were clarified in relation with microstructure. Particular emphasis was placed on roles of bands of pearlites or C- and Mn-rich regions and complex iron oxides present in the edge side. Pearlite bands in the cracked region were considerably bent to the surface, while those in the noncracked region were parallel to the surface. This was because the alignment direction of pearlite bands was irregularly deviated up to 45 deg from the normal direction parallel to the surface, while the billet was rolled and rotated at 90 deg in the same direction between rolling passes. On the edge side, where pearlite bands were bent, iron oxides intruded deeply into the interior along pearlite bands, which worked as stress concentration sites during hot rolling and, consequently, main causes of the crack initiation in the rolled billet. On the surface of the wire rod rolled from the cracked billet, a few scabs were found when some protrusions were folded during hot rolling. In order to prevent the cracking in billets and scab formation in wire rods, (1) the increase of rolling passes and the decrease of reduction ratio for homogeneous rolling of billets and (2) the reduction in sulfur content for minimizing the formation and intrusion of complex iron oxides were suggested.     

CSP连轧过程金属变形的热力耦合模拟分析

借助Marc商用软件,采用弹塑性大变形热力耦合有限元法(FEM),对包钢生产的1 500 mm×68mm薄板坯CSP(紧凑式带材生产)轧制第一道次的热轧过程进行了模拟。分析了变形区内轧材等效应力场、应变场及应变速率的分布和变化规律。结果表明在轧件变形区内,等效应力沿轧制方向逐渐增大,在中性面附近达到最大值(95.20 MPa),后又逐渐减少;等效应变亦沿轧制方向逐渐增大,在轧件出口处达到最大值(0.70);在轧件入口端表面附近等效应变速率有最大值,为20.74 s^-1。模拟计算的轧制力为22 203 kN,现场测得的轧制力为22 239 kN,预测误差为0.16%。     

Crystallographic preferred orientation induced by cyclic rolling contact loading

Fine focus X-ray diffraction methods have been applied to analyze the texture development of the ferrite phase during rolling contact fatigue of 6309 type deep groove ball bearing inner rings prepared from hardened and tempered SAE 52100 steel. Textures of the ferrite matrix as {100}〈110〉 and {111}〈211〉 (where {hkl} denotes the crystallographic plane that is preferably parallel with the contact surface and 〈uvw〉 denotes the crystallographic direction that is preferably parallel with and in the direction of over-rolling) have been identified in a small region below the rolling contact surface. These textures develop gradually with an increasing number of stress cycles and become noticeable in conjunction with changes in residual stress, microstrain, and volume fraction of retained austenite in the same region. Upon rolling contact loading, both textures can become very pronounced, while the shape of the subsurface volume, where plastic deformation takes place in particular, remains unchanged: material displacement in the subsurface volume is less than 5 μm in the three principal directions. Crack propagation in association with spalling fatigue failure has been shown to be related to the type of texture developed.     

Optimization of Holding Temperature and Holding Thickness for Controlled Rolling on Plate Mill

Holding temperature and holding thickness are main parameters for two-phase controlled rolling on plate mill. The optimization of holding temperature and holding thickness for pass schedule calculation of two-phase controlled rolling on plate mill was presented and its feature is as follows： （1） Determination of holding thickness can be automatically obtained based on the influence of mill safety limits, tracking zone length and holding time on holding thickness; （2） Determination of holding temperature can be automatically obtained and the holding time can be reduced as much as possible; （3） Algorithm can modify the holding temperature and thickness depending on slab size and product size.     

生产工艺对320MPa高强度船板钢低温冲击韧性的影响

采用不同的生产工艺制度,E32级船板钢在工业试制过程中的-40℃纵向冲击功波动较大,对此现象的研究表明,在采用两阶段轧制时,由于中间坯的厚度较大,对未再结晶区的变形温度产生影响,易发生在部分再结晶区轧制时,钢板出现混晶,从而造成钢板低温冲击值较低。     

Surface-crack formation in the manufacture of microalloyed steel pipe

Deform-3D software is used to model surface-crack formation in the rolling of thick sheet on a 5000 mill. The calculations show that the temperature field and stress state are relatively uniform over the width of the sheet, except at the edges. The minimum temperature of the surface layers of metal hardly depends on the sheet thickness and the relative reduction per pass. The Cockroft–Latham criterion is used to analyze the probability of steel failure in rolling. Analysis shows that metal failure may occur at points where ferrite appears, especially at the instant that the metal leaves the deformation region. Considerable tensile stress acts at those points.     

Analysis of Crack Tip Stress of Transversal Crack on Slab Corner During Vertical-Horizontal Rolling Process by FEM

Behavior of transversal crack notched on slab corner during vertical-horizontal rolling process was simulated by FEM. The crack tip stress in the whole rolling process was obtained. Influences of the friction coefficient, the initial crack size, the edger roll profile, and the groove fillet radii of grooved edger roll on crack tip stress were analyzed. For vertical rolling, the tension stress appears at crack tip near the slab top surface and the compression stress appears at crack tip near the slab side surface for the flat edger roll; however, the compression stress appears at crack tip near the slab top surface and the tension stress appears at crack tip near the slab side surface in the exit stage for the grooved edger roll. For horizontal rolling, the tension stress appears at crack tip just at the exit stage for the flat edger roll, and the tension stress appears in whole rolling stage; the tension stress value near the slab side surface is much larger than that near the slab top surface for the grooved edger roll.     

Numerical Simulation of Temperature Field and Thermal Stress Field of Work Roll During Hot Strip Rolling

  Based on the thermal conduction equations, the three dimensional (3D) temperature field of a work roll was investigated using finite element method (FEM). The variations in the surface temperature of the work roll during hot strip rolling were described, and the thermal stress field of the work roll was also analyzed. The results showed that the highest roll surface temperature is 593 ℃, and the difference between the minimum and maximum values of thermal stress of the work roll surface is 1457 MPa. Furthermore, the results of this analysis indicate that temperature and thermal stress are useful parameters for the investigation of roll thermal fatigue and also for improving the quality of strip during rolling.     

钛合金斜轧穿孔温度预测方法研究

钛合金因具高韧性、耐腐蚀性能好、强度高、焊接能力好的优势而逐渐被应用于我国海洋和船舶领域,对我国科技发展和科技强国有积极的促进作用。本文以三维有限元模拟试验为基础,分析了斜轧穿孔温度对钛合金显微组织和性能的影响,结果表明:在单相变形区内,钛合金的流动应力和应变速率变化范围较小,在单相区1050℃和1100℃内均能顺利完成斜轧穿孔试验,在两相区950℃内无法完成斜轧穿孔试验,最终确定该类钛合金的斜轧穿孔温度为1050℃。     

Effective grain size and charpy impact properties of high-toughness X70 pipeline steels

The correlation of microstructure and Charpy V-notch (CVN) impact properties of a high-toughness API X70 pipeline steel was investigated in this study. Six kinds of steel were fabricated by varying the hot-rolling conditions, and their microstructures, effective grain sizes, and CVN impact properties were analyzed. The CVN impact test results indicated that the steels rolled in the single-phase region had higher upper-shelf energies (USEs) and lower energy-transition temperatures (ETTs) than the steels rolled in the two-phase region because their microstructures were composed of acicular ferrite (AF) and fine polygonal ferrite (PF). The decreased ETT in the steels rolled in the single-phase region could be explained by the decrease in the overall effective grain size due to the presence of AF having a smaller effective grain size. On the other hand, the absorbed energy of the steels rolled in the two-phase region was considerably lower because a large amount of dislocations were generated inside PFs during rolling. It was further decreased when coarse martensite or cementite was formed during the cooling process.     

Analysis on Shear Deformation for High Manganese Austenite Steel during Hot Asymmetrical Rolling Process Using Finite Element Method

Based on the rigid-plastic finite element method(FEM), the shear stress field of deformation region for high manganese austenite steel during hot asymmetrical rolling process was analyzed. The influences of rolling parameters, such as the velocity ratio of upper to lower rolls, the initial temperature of workpiece and the reduction rate, on the shear deformation of three nodes in the upper, center and lower layers were discussed. As the rolling parameters change, distinct shear deformation appears in the upper and lower layers, but the shear deformation in the center layer appears only when the velocity ratio is more than 1.00, and the absolute value of the shear stress in this layer is changed with rolling parameters. A mathematical model which reflected the change of the maximal absolute shear stress for the center layer was established, by which the maximal absolute shear stress for the center layer can be easily calculated and the appropriate rolling technology can be designed.     

Effect of thermomechanical factors on the properties of steel 15GFB

Such factors of thermomechanical treatment as the number of deformations, the length of time between them, and the temperature at the end of deformation are important in determining the optimum parameters of controlled rolling. Studies have shown that in order to obtain steel with a fine-grained ferritic-pearlitic structure having a developed substructure, it is necessary to repeatedly deform the semifinished product 15–33% in each pass within the temperature range 800–1150°C. Controlled rolling of the investigated low-alloy steel in the two-phase region ensures that the finished steel will have high strength characteristics.