Measurements of friction in cold flat rolling

The effect of reduction, rolling speed and material properties on the variation of interfacial frictional and normal stresses in the roll gap during cold flat rolling is studied. The results confirm the conclusions of earlier research, emphasizing the dependence of the coefficient of friction, and hence the interfacial shear stress, on the process parameters. Preliminary experiments, using mineral oil with 1% oleic acid as lubricant, show the possible existence of hydrodynamic lubrication, at least over part of the contact area. The validity of the data is substantiated by comparing the roll separating forces, measured by transducers located under the bottom workroll, to those obtained by integrating the measured roll pressure distribution over the arc of contact. The comparison is found to be favorable, indicating that in spite of its shortcomings, the embedded pin technique gives reliable measurements.     

Microstructural development during warm rolling of an IF steel

Wedge-shaped slab rolling was employed to investigate the microstructural evolution of an interstitial-free (IF) steel during warm working in the temperature range 500–800°C. Mean flow stress-strain curves calculated from load-time data of rolling tests reasonably correspond to work hardening and dynamic recovery behaviour. The development of substructures in the deformed material was investigated using optical and electron microscopy. A close correlation was observed between mechanical behaviour and microstructural development during deformation. Microbands in directions of ± 35° with respect to the rolling direction, independent of strain, temperature and initial grain orientations are the most noticeable features in the microstructural observations. The sequences of substructural changes from the appearance of early microbands at very low strains, their development with strain, to the formation of equiaxed subgrains at higher strains and temperatures were followed by TEM.     

Effect of roll gap adjustment on exit cross sectional shape in groove rolling—Experimental and FE analysis

We machined work roll with groove worn down as well as groove with no wear. We then performed a pilot hot rod rolling test at temperature of 1000 °C using plain carbon steel (0.1% C) as the roll gap decreases from reference roll gap (6.5 mm) to 3.5 mm. To understand better the effect of roll gap (i.e., section height) adjustment on the exit cross sectional area (ECSA) variation of workpiece in a two-stand groove rolling process with wear is considered, we carried out a series of three dimensional finite element analysis. Results reveal that variation of ECSA is almost linearly proportional to roll gap change while the roll gap decreases from reference roll gap (6.5 mm) to 3.5 mm. In oval groove rolling, the exit cross sectional shape and area predicted by FEA is in a good agreement with those measured. In round groove rolling, however, some deviations between FEA and experiment are observed because of roll groove geometry coupled with cross sectional shape of incoming workpiece. In the two-stand groove rolling, the effect of roll gap adjustment at each stand on the exit cross section of workpiece is somewhat different, in comparison with single-stand groove rolling. The roll gap adjustment at the previous stand has a more influence on the ECSA of workpiece than that of the next stand.     

变形参数对半固态轧制影响规律的有限元模拟

建立了半固态材料刚 -粘塑性分析模型 ,以高温钢铁材料为研究对象 ,用MARC软件模拟分析了半固态轧制时 ,轧辊辊缝、轧辊转速等变形参数和浆料初始温度对应力场、速度场的影响 ;结合有限元模拟结果 ,进行了半固态实际轧制试验。实际轧制试验表明 ,轧辊辊缝、轧辊转速和浆料初始温度对半固态轧制试验的影响规律基本与有限元模拟一致 ,其中浆料初始流入速度和温度控制是保证半固态轧制过程顺利进行的关键     

斜轧锚杆轧制压力影响因素实验分析

轧制力是斜轧锚杆工艺设计的重要参数,轧制力的变化受到各工艺参数的影响.本文通过实验测定了斜轧锚杆过程中不同参数下轧制力的大小,结合实验结果分析了斜轧锚杆过程中各影响因素对轧制力的影响规律,得出了各因素对轧制力影响的主次关系,其中轧件壁厚影响最大,其次是轧件外径和材料,导板间隙对轧制力几乎没有影响.本文为斜轧锚杆的设计研究提供了一定的理论依据.     

Dynamic explicit FE modeling of hot ring rolling process

1Introduction Ring rolling is an advanced process typically used to manufacture parts with revolved geometries.It makes use of rotating rolls to press a ring continuously and locally,causing the wall thickness of the ring to reduce,the diameter to expand …     

车轮轧制成形过程的有限元模拟

采用DEFORM-3D建立车轮轧制过程三维有限元分析模型,在建立轧制过程的数学模型和开发轧辊运动的控制算法,并与DEFORM软件集成的基础上,模拟了实际轧制过程中轧辊的运动。从轧制力对比与轮坯几何形状的分析两方面验证了模型和控制算法的可靠性;分析了轧制过程中材料的流动规律,为改进轧制工艺提供了参考。     

Micro scale design and experimental research of rolling interface

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Formation of Nano/Ultrafine Grains in AISI 321 Stainless Steel Using Advanced Thermo-Mechanical Process

Production of nano/ultrafine grains through deformation-induced martensite formation and its reversion to austenite in an AISI 321 stainless steel was studied.The repetitive cold rolling and subsequent annealing were conducted to obtain nanocrystalline structure.Heavy cold rolling(90% reduction) at ?20 and-20 °C was carried out to induce the formation of a9-martensite from metastable austenitic material.The process was followed by annealing treatment at700–900 °C for 0.5–30 min.Effects of process parameters,i.e.,‘‘reduction percentage,' ‘‘rolling temperature,' ‘‘annealing temperature' and ‘‘annealing time',on the microstructural development were considered.Microstructural evolutions were conducted using feritscope,X-ray diffractometer and scanning electron microscope.Hardness of the specimens was measured by Vickers method.Results revealed that the higher thickness reduction and lower rolling temperature provided more martensite volume fraction and further hardness.X-ray diffraction patterns and feritoscopic results indicated that saturated strain(es) was reduced from 2.3 to 0.9 when temperature declined from ?20 to-20 °C.The smallest grain size(about 70 nm) was achieved in the condition of cold rolling at-20 °C followed by annealing at 750 °C for 5 min.     

冷轧机轧制过程中的轧辊振动研究

以冷轧机轧辊垂直振动为研究对象,在分析冷轧机振动机理的前提下,建立轧机垂直振动简化模型,运用数值仿真方法,分析了轧制压下量、摩擦系数及辊缝阻尼的轧制工艺参数对轧机垂直振动的影响。分析结果表明:减小轧机压下量有利于提高轧机振动临界速度;增加辊缝摩擦系数有利于减小轧辊的振动位移;增加辊缝阻尼能够有效降低振动幅值。在此基础上提出了抑制冷轧机垂直振动方法为:优化各道次压下量,以使轧制临界速度由1340 m·min-1提升到1520 m·min-1;适当降低乳化液浓度,以使辊缝摩擦系数增大,此调节过程应考虑窜流现象;增设液压衬板减震器或多孔阻尼减震器,以增加辊缝阻尼。     

Stability of rolling texture during heat treatment in a two-phase Ti3Al base intermetallic alloy

The stability of hot rolling texture developed in the ₂ phase of a two-phase Ti₃Al base intermetallic alloy, during subsequent heat treatment, has been systematically investigated. The basal hot rolling texture remains rather stable during recrystallization annealing at temperatures within the single phase ₂ range. Grain growth after recrystallization produces extra orientations other than the basal. For the material with a starting basal texture, heat treatment in the upper ₂, (₂+β) or β phase fields does not change the basic character of the texture, although the sharpness and especially the width of the basal component increase to some extent with the increase in the heat treatment temperature. Heat treatment of material with starting non-basal texture in the upper ₂, (₂+β) or β phase fields does not produce any basal component irrespective of the heat treatment temperature. When the starting material is reasonably strain free and possesses a weak basal texture, heat treatment in the upper ₂, (₂+β) or β phase fields helps in intensifying the basal component to a certain extent.     

Ring rolling process simulation by the three dimensional finite element method

The finite element code “RING” was developed for the analysis of ring rolling. A special feature of the program is the updating procedure in three-dimensional deformation. A spatially fixed mesh system including deforming region of the workpiece is constructed based on the shape changes of the ring at each time step. Several simulations are performed with the program “RING”, and the results are compared with experimental data found in the literature. Good agreement between the simulation results and experiments was obtained in terms of geometrical changes of rings in plain ring rolling and T-shaped profiled ring rolling.     

An experimental study of the mean effective strain in rod (or bar) rolling process

This paper presents an experimental study that investigates the validity of the analytical model [9] for predicting the mean effective strains associated with bar (or rod) rolling. Designed for this purpose were plate and bar rolling experiments which consist of a four-pass groove (oval and round) rolling sequences, which have material at each pass that experience the same amount of mean effective strain. The microstructure and mechanical behaviors of specimens acquired from two types of rolling experiments at 650°C were compared. A parallelism between the mechanical behaviors of a plate-rolled specimen and a bar-rolled specimen has been found at each pass. We therefore concluded that the analytical model has the underlying rationale to be used in the analysis of the rod (or bar) rolling process.     

FEM analysis for V–H rolling process by updating geometric method

Three passes of slab rolling during vertical–horizontal rolling process were simulated with explicit dynamic FEM by updating geometric method. Simulation model of the next pass was built when the rolling geometry model was updated after previous pass was finished, changing roll gap, material attribution and boundary conditions. The calculated results of the slab shape are in good agreement with the experimental ones. It is shown that the explicit dynamic FEM and updating geometric method can be used effectively to analyze the multi-passes of V–H rolling process.     

Prediction of effect of rolling speed on coefficient of friction in hot sheet rolling of steel using sliding rolling tribo-simulator

In order to reduce the rolling force and the roll wear, the lubricants have been used in hot rolling of steel. In order to evaluate the tribological behavior at the interface between roll and workpiece in hot steel rolling, it is important to measure the coefficient of friction and examine the effect of the tribological factors on the coefficient of friction. In this paper, the effect of the rolling speed on the coefficient of friction is investigated using the tribo-simulator testing machine for hot rolling developed by the authors. The workpiece used is SPHC. The roll material is SKD11 and the surface roughnesses are 0.05 μm, 0.2 μm and 0.8 μm. The rolling tests are carried out at a temperature of 800 °C during a rolling distance of 400 mm, changing the rolling speed from 15 to 70 m/min. The colza oil is used as a base oil and the emulsion concentrations are 0.1% and 3.0%. The coefficient of friction at an emulsion concentration of 3.0% is independent on the rolling speed. On the other hand, the coefficient of friction at an emulsion concentration of 0.1% decreases with increasing rolling speed in the lower range of rolling speed, but it increases in increasing rolling speed in the higher range of rolling speed.     

冷轧对G20CrNi2MoA渗碳轴承钢组织演变与耐磨性的影响

采用电子背散射衍射分析(EBSD)、扫描电镜(SEM)、X射线能谱分析(EDS)等方法研究了冷轧对G20CrNi2MoA渗碳轴承钢微观组织演变规律和耐磨性的影响。结果表明:冷轧能够细化原材料晶粒;当冷轧变形量由0%增加到30%时,经二次淬火后,表层碳化物面积分数由4.38%增加到5.99%,碳化物平均粒径由0.15 μm降低到0.13 μm;经二次低温回火后,表层约0.9 mm渗碳层深范围内碳含量梯度和显微硬度梯度得到提高,平均摩擦因数由0%的0.489降低到30%变形量下的0.346,磨损率由27.2×10^-6 mm³·N^-1·m^-1降低到9.1×10^-6 mm³·N^-1·m^-1。表明材料经30%冷轧变形后,由于表层碳化物的面积分数和硬度得到提高,磨粒磨损和疲劳磨损逐渐减轻,使耐磨性得到提高。     

Microstructural characterization of Zr1Nb alloy after hot rolling

The nuclear industries have large interest on the development of new alloys involving zirconium (Zr) because this material presents extraordinary mechanical properties, outstanding resistance to corrosion and high permeability to thermal neutrons, being suitable for applications in areas such as energy and human health. The alloy studied in this paper is formed by Zr and niobium (Nb), normally expressed as Zr1Nb. These two elements have large chemical affinities with oxygen, carbon, and nitrogen, elements that normally are responsible for a series of damages in the alloy. The principal goal of this work is to obtain Zr1Nb alloys and to perform microstructural characterizations before and after the hot rolling process. The resulting alloys were subjected to a process of heat treatment, the temperature was increased at a rate of 10 K/min up to 1273 K and maintained for 2 h, after which it was cooled down at −10 K/min until room temperature, with the only purpose of relieving residual stresses. The next step was to apply the hot rolling process to the alloy. The sample initially measured, approximately, 1.5 cm of thickness when it was inserted into the furnace at 1203 K to start the hot rolling. Every pass on the hot rolling reduced the thickness by 0.5 mm, originating uniform and homogeneous samples of 2.5 mm thickness. Auxiliary technical tools, such as XRD (X-Ray Diffraction), SEM (Scanning Electron Microscopy), and EDS (Energy Dispersive X-Ray Spectroscopy), were used to analyze the microstructure of the samples before and after the hot rolling process. The XRD results show the formation of only a single α-HCP (Hexagonal Close Packed) phase for our samples, indicating that they are free of other phases that can damage the material. This result is consistent and coherent with both SEM and EDS analysis. The observed homogeneity of our samples is very good; proving that both techniques employed to obtain Zr1Nb as well as the hot rolling process was well succeeded. Therefore, the obtained alloy can be directly used in the pipes of nuclear combustible industries.     

轧前深冷处理对AZ31镁合金显微组织和力学性能的影响

本文通过对铸态AZ31镁合金经不同条件的深冷处理继而热轧,分析其强度、韧性、延展性效应及其规律。深冷实验条件分别为-60℃/12h、-120℃/12h、-180℃/12h、-60℃/2h和-180℃/2h。结果表明：AZ31经适宜的深冷处理,晶粒得到细化,强度、韧性及延展性得到有效提高;与未经深冷处理试样相比,深冷处理时间为2h的两种试样中都出现大量孪晶;经-60℃/12h深冷处理后再进行轧制试样的显微组织最为细小均匀,屈服强度提高了25.8%,而延伸率则更是提高了4倍,由3.06%提高到了12.31%;深冷处理后的AZ31镁合金断口呈现出脆性断裂和塑性断裂集合的复合性断裂特征。     

Influence of rolling route on microstructure and mechanical properties of AZ31 magnesium alloy during asymmetric reduction rolling

Four different routes of asymmetric reduction rolling were conducted on AZ31 magnesium alloy to investigate their effect on the microstructure evolution and mechanical properties. Route A is the forward rolling; while during routes B and C the sheets are rotated 180° in rolling direction and normal direction, respectively; route D is the unidirectional rolling. The strain states of rolled sheets were analyzed by the finite element method, while the microstructure and texture were observed using optical microscopy, X-ray diffraction and electron back-scattered diffraction techniques, and the mechanical properties were measured by tensile test. The results show that route D produced the largest effective strain. Compared with other samples, sample D exhibited a homogeneous microstructure with fine grains as well as a weak and tilted texture, in corresponding, it performed excellent tensile properties, which suggested that route D was an effective way to enhance the strength and plasticity of AZ31 sheet.     

Analysis of asymmetrical hot strip rolling by the slab method

Two analytical models based on the slab method are proposed to examine the behavior of sheet at the roll gap during the asymmetrical hot strip rolling process. In model I, the effect of shear stress in vertical plane at the roll gap is considered, whereas this effect is neglected in model II. Neutral points between rolls and strip, rolling pressure distributions along the contact art length of rolls, rolling forces, and rolling torques can be calculated easily by these proposed analytical models. The results including rolling pressure distributions, rolling forces, and rolling torques by both models are compared. The rolling pressure distribution predicted by model I shows that a “pressure well” develops in the cross shear region. On the other hand, no “pressure well” is predicted in model II. Furthermore, the rolling forces predicted by model I are always lower than those measured in the experiment, whereas those predicted by model II are always higher. However, the averages of the values predicted by model I and II are in fairly good agreement with the experimental data. Thus this analytical approach can offer useful knowledge in designing the pass schedules of the asymmetrical hot strip rolling processes.