Performance Analysis of Hot Rolling Mill Rolls to Improve the Productivity of the Rolling Process Using Fem
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Date
2015-11
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Addis Ababa University
Abstract
The main objective of rolling theory is to predict the manner of the plastic deformation. In hot rolling the chief factors influencing the yield stress are the nature of the material, the temperature at which the material is rolled and the strain rate, i.e. the rate of deformation. And also the main factors that influence the mechanics of rolling may be listed as follows: the roll diameter, reduction in one pass, the initial thickness of the stock, the speed of rolling (which decides the strain rate), the nature of friction between the rolls and the material rolled, the temperature field in the billet and the rolls, the mill behavior under load, the aspect ratio, or the ratio of the width of stock to the initial thickness, etc..). Those factors creates secondary parameters and phenomena more directly related to and commonly associated with the rolling process, such as: Coefficient of draught, Spread, Coefficient of elongation, Bite angle, roll gap, slip, roll pressure, torque, work and power which are influenced by the above factors.
This thesis is to analyze the deformation of billet size 120x120x3000mm, modeling and Simulation of hot rolling roughing mill first pass by finite element method. To do this three dimensional roll and billet was developed in CATIA version 5. This 3D model was imported to ANSYS work bench 16.0. FEM analysis was done after assigning, boundary conditions, displacement, rotational velocity, and load.
From the simulated results, the Directional Deformation and Equivalent Stress for the hot rolling of billet can be worked out. The hot continuous rolling process are simulated to analyze the cause of Deformation considering the roll pass design parameters, then the roll pass optimization is worked out based on the analysis of the deformation of billet with rolls. This simulation results are verified by the actual test stress vs. Strain curve.
Keywords: Steel Industry, roll pass design, rolling process, Coefficient of draught, Spread,
Coefficient of elongation, Bite angle, rolls gap and slip.
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Keywords
Steel Industry;roll pass design; rolling process; Coefficient of draught; Spread;Coefficient of elongation; Bite angle; rolls gap and slip