Analysis of profile and flatness in flat hot rolling based on non linearly coupled models for elastic roll stack deflection and pseudo-steady-state elasto-viscoplastic strip

An enhanced iterative concept for the effective numerical simulation of flat hot rolling processes is presented. The underlying physical process is the forming of metal within a flat rolling stand, i.e. between a lower and an upper roll set, each of them consisting of one or more rolls. The strip material is described elasto-viscoplastically, whereas the roll stack is deformed elastically. The accurate coupling of the strip model with the routines for the elastic roll stack deflection is a precondition to get reliable results concerning profile transfer and incompatible residual strains inside the strip, which allows the prediction of flatness defects, such as buckling. Especially for thin, wide strips and heavy plates, where the aspect ratio width over thickness is extremely unfavourable, the determination of profile transfer and flatness bviously leads to extremely high calculation times with commercial FEM-programs. Therefore, a tailor-made FEM-code for the efficient simulation of the elasto-viscoplastic material flow inside the roll gap was developed and programmed in C++. It is based on pseudo-steady-state, fully implicit stress-update approaches, where the incremental material objectivity is satisfied exactly. The developed model is well suited for systematic parameter studies to investigate flatness defects in more detail and to develop enhanced flatness criteria for thin hot and cold strips and plates

Analysis of profile and flatness in flat hot rolling based on non linearly coupled models for elastic roll stack deflection and pseudo-steady-state elasto-viscoplastic strip

An enhanced iterative concept for the effective numerical simulation of flat hot rolling processes is presented. The underlying physical process is the forming of metal within a flat rolling stand, i.e. between a lower and an upper roll set, each of them consisting of one or more rolls. The strip material is described elasto-viscoplastically, whereas the roll stack is deformed elastically. The accurate coupling of the strip model with the routines for the elastic roll stack deflection is a precondition to get reliable results concerning profile transfer and incompatible residual strains inside the strip, which allows the prediction of flatness defects, such as buckling. Especially for thin, wide strips and heavy plates, where the aspect ratio width over thickness is extremely unfavourable, the determination of profile transfer and flatness bviously leads to extremely high calculation times with commercial FEM-programs. Therefore, a tailor-made FEM-code for the efficient simulation of the elasto-viscoplastic material flow inside the roll gap was developed and programmed in C++. It is based on pseudo-steady-state, fully implicit stress-update approaches, where the incremental material objectivity is satisfied exactly. The developed model is well suited for systematic parameter studies to investigate flatness defects in more detail and to develop enhanced flatness criteria for thin hot and cold strips and plates

Modular Finite Element Modeling of Heavy Plate Rolling Processes Using Customized Model Reduction Approaches

Heavy plates are indispensable semi-finished products. Quality is strongly linked with production, so the rolling process must be performed within well-defined narrow tolerances. To meet this challenge, adequate modeling has become a necessity. In contrast to continuous strip rolling, where the workpiece can be modeled as a semi-infinite strip and 2D modeling can be argued quite well, this strategy is insufficient for the comprehensive modeling of heavy plate rolling. The geometry of the heavy plate favors an inhomogeneous distribution of relevant state variables, such as temperature. In addition, if the process involves longitudinal and spreading passes, the required plate rotation spoils the assumption of a symmetric arrangement that might have been acceptable before rotation. Consequently, the derivation of suitably reduced models is not trivial, and modeling tailored to the specific objective of investigation is of utmost importance. Models intended to resolve the evolution of inhomogeneities in the field variables are demanding and computationally expensive. An effective modular modeling strategy was developed for such models to be used offline. Mutually complementing and interchangeable modules may constitute an efficient modeling strategy valid for the specific subject of interest. The presented approach reduces the enormous cost of complete 3D simulation as much as the model purpose allows for