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Abstract
In both rolling theory and practice, two important factors must be considered: friction and deformation resistance strength. A major
handicap to producing accurate and reliable models for hot strip rolling is the lack of well-dened friction boundary conditions. In order to
improve the accuracy of the computer on-line control model, in this paper, the authors developed a 3D rigidvisco-plastic nite element
method (FEM) model to simulate the hot rolling of strip, considering dry and lubricated conditions. The simulation was based on the
experimental conditions conducted on a Hille 100 experimental mill. Rolling pressure was measured by a sensor roll that includes a radial pin
and an oblique pin. A comparison of the simulation results and experimental values, such as roll separating force and torque, taking into
account the friction variation in the roll bite shows a good agreement. The application of lubrication in hot strip rolling can reduce the roll
separating force, and the rolling speed also has a signicant inuence on the roll separating force.
# 2002 Elsevier Science B.V. All rights reserved.
Keywords: Friction variation; Lubrication; Hot rolling; Finite element analysis
1. Introduction
The technology of the hot rolling of steel strip is well
understood by researchers and engineers of the steel industry
[1] and renement of the process may contribute, in a
signicant manner, to cost reduction and improvement of
the quality of the surface. By improving the rolling conditions at the interface of the strip and rolls, such as lubrication
in the roll bite, the rolling load can be reduced and quality of
surface can be improved signicantly. The cost associated
with the frequency of roll change due to wear has been
estimated to be as much as 10% of the total process [1]. Zhu
et al. [2] determined the lm thickness using oil-in-water
emulsions under elasto-hydrodynamic lubrication in cold
rolling. Luong and Heijokoop [3] concluded that in respect
to friction, the scale thickness appears to be more important
than scale composition. In a recent study, Jarl [4] estimated
the mechanical properties of the scale in hot rolling, and
found that if the scale thickness is low it cannot act as a
lubricant. Munther and Lenard [5] found that in the hot
rolling of low carbon steels, the thicker scale leads to a lower
frictional resistance. The present work will focus on the hot
rolling of strip with lubrication.
*
Corresponding author. Tel.: 61-2-4221-3061; fax: 61-2-4221-3101.
E-mail address: ktieu@uow.edu.au (A.K. Tieu).
0924-0136/02/$ see front matter # 2002 Elsevier Science B.V. All rights reserved.
PII: S 0 9 2 4 - 0 1 3 6 ( 0 2 ) 0 0 3 7 1 - 0
A.K. Tieu et al. / Journal of Materials Processing Technology 125126 (2002) 638644
2. Theoretical analysis
2.1. Slightly compressible method formulation
The slightly compressible method in 3D rigidvisco-plastic
FEM has been employed to solve many rolling problems.
According to the variational principle [34], the real velocity
eld must minimise the following functional:
Z Z Z
Z Z
Z Z
F
se_ dv
tf DVf ds
tK DVK ds
v
Z Z
sf
sK
T1 v ds fp ff fj ft
(1)
sv
where the rst term on the right-hand side is the work rate of
plastic deformation (fp), s the equivalent stress and e_ the
equivalent strain rate. The second term on the right-hand
side is the work rate of friction (ff); DVf is the relative slip
velocity on the interface of the rolled material and the rolls
where the frictional shear stress tf is applied. To take into
account the friction variation in the roll bite, in this study
the modied frictional stress model [6] can be written as
follows:
m1 ss 2
1 Vg
tf Ki p
tan
(2)
k1
3 p
where m1 is the friction factor; ss the yield stress; Ki a
coefcient describing the changes of frictional shear stress in
the deformation zone, which has two parameters K1 and K2
for the forward slip zone and backward slip zone, respectively, k1 is a small positive constant. The distribution of the
frictional shear stress can be seen in Ref. [30]. The relative
slip velocity, Vg, between the rolled material and roll is
calculated by
q
Vg vx sec b VR 2 vy 2
(3)
where vx and vy are the velocity components in the x and y
directions, respectively; b the angular position of the node;
VR the tangential velocity of the roll. DVf is also the relative
slip velocity between the rolled material and roll, which can
be calculated by
q
DVf vx sec b VR 2 v2y k22
(4)
where k2 is a small positive constant to prevent a second
singular point during simulation [7]. The third term on the
right-hand side of Eq. (1) is the additional shearing work rate
(fj) at a surface on which there is a velocity discontinuity.
DVK is the velocity discontinuity across the velocity discontinuity surface sK within the volume V, tK is the shear
stress, tK K (K is the shear yield stress). The fourth term
on the right-hand side is the work rate (ft) of tension. T1 is
the tension and v is the velocity of the cross-section with
tension. Here `` '' indicates the forward tension, and ``''
the backward tension. When the functional F is minimised
by the rigidvisco-plastic FEM using the formulation for
639
(9)
0:05
(11)
(12)
C 0:09
640
A.K. Tieu et al. / Journal of Materials Processing Technology 125126 (2002) 638644
m 0:081C 0:154T
0:027
C 0:32
Table 1
Velocity boundary conditions (see Fig. 1)
0:019C 0:207
(15)
and
f 1:35en 1:5e;
T1 273
T
1000
n 0:41
0:07C;
(16)
Position
Velocity component
AA1B1B
EHH1E1
CDD1C1
BCC1B1
HH1A1A
EHAB
vy vz 0
vy vz 0
vz =vx tg b
vz 0
vz 0
vy 0
A.K. Tieu et al. / Journal of Materials Processing Technology 125126 (2002) 638644
641
Table 2
Chemical composition of the tested steel
Grade
C
(Max)
Si
(Max)
Mn
(Max)
P
(Max)
S
(Max)
Al
(Max)
Ti
(Max)
250
0.22
0.55
1.7
0.04
0.035
0.1
0.04
4. Results
4.1. Experimental results
The rolling pressure distributions can be obtained from
the sensor roll, and then the friction coefcient can be
calculated from Eq. (17) [36], as follows:
m
py =p 1
tan y
(17)
Fig. 5. Friction coefficient for reduction 17.5%: (a) dry; (b) lubricated.
642
A.K. Tieu et al. / Journal of Materials Processing Technology 125126 (2002) 638644
Fig. 9. Effect of the rolling speed on roll separating force without lubrication.
A.K. Tieu et al. / Journal of Materials Processing Technology 125126 (2002) 638644
643
Fig. 10. Effect of the reduction on the roll separating force with oil
lubrication.
Fig. 11. Effect of the reduction on roll separating force for different rolling
temperatures.
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A.K. Tieu et al. / Journal of Materials Processing Technology 125126 (2002) 638644
[26]
[27]
[28]
[29]
[30]
[31]
[32]
[33]
[34]
[35]
[36]