Abstract
The present work aims at the modelling and simulation of the hot rolling process for wire rod and bars. After the fundamentals of plasticity, which are essential for the understanding of the process characteristics have been described, typical section deviations that can be expected in wire rod and bar mills are calculated with help of a numerical simulation model. The model allows the calculation of section shapes under the influence of elastic rolling stand deformations and interstand tensions. From this computational assessment of section faults, the necessity of inline measurement and process control for wire rod and bar mills is shown. This work is part of the PIREF project which incorporates the development of sensors, control systems and process models in order to control the dimensional accuracy of hot rolled wire rod and bars. The metal forming process model, as described here is used internally as a model for the static and kinematic interactions in the rolling process inside of the control model.
Zusammenfassung
Der vorliegende Beitrag beschäftigt sich mit der Modellierung und Simulation des Warmwalzprozesses für Stabstahl und Draht. Nachdem die für das Prozessverständnis essenziellen Grundlagen der Umformtechnik erläutert worden sind, werden mit einem numerischen Modell berechnete Querschnittsabweichungen präsentiert, die bei warmgewalztem Stabstahl und Draht erwartet werden können. Das Modell erlaubt die Berechnung der gewalzten Querschnittsformen unter dem Einfluss von elastischer Gerüstauffederung und Längszügen. Aus diesen rechnerischen Ergebnissen kann die Notwendigkeit einer Inline-Regelung der Profilquerschnitte abgeleitet werden. Die vorliegende Arbeit ist Teil des Forschungsprojektes PIREF, welches die Entwicklung von Sensoren, Regelsystemen und Prozessmodellen beinhaltet, um die Maßhaltigkeit gewalzter Vollquerschnitte regeln zu können. Das hier beschriebene Umformmodell wird im Rahmen des Regelmodells benutzt, um die statisch-kinematischen Abhängigkeiten des Walzprozesses zu beschreiben.
Funding source: European Regional Development Fund
Award Identifier / Grant number: MP-1-2-002a
Funding statement: The authors wish to thank the European Regional Development Fund EFRE.NRW for funding of the project PIREF with funding reference no. MP-1-2-002a.
About the authors
Christian Overhagen was born in 1981 and studied Metallurgy and Metal Forming at the University of Duisburg-Essen and the Clausthal University of Technology. He graduated in 2005 with a Bachelor of Engineering and 2011 with a Master of Science degree, both with final theses about the mathematical modelling of hot and cold rolling processes. Christian Overhagen pursued a Doctor of Engineering degree in 2018 at the University of Duisburg-Essen with a work on mathematical modelling and simulation for rolling processes of flat and full sections. Christian Overhagen currently works at the chair of Metal Forming in the Institute for Technology of Metals of the University of Duisburg-Essen as a scientific associate.
Rolf Braun was born in 1985 and studied Mechanical Engineering at the University of Applied Sciences Offenburg and graduated as a Bachelor of Engineering in 2010 with a Bachelor Thesis about non-destructive testing of rolling mill rolls. He works as a scientific associate at the Chair of Metal Forming in the Institute for Technology of Metals of the University of Duisburg-Essen and is currently pursuing his Master of Science degree in the field of metal forming.
Rüdiger Deike was born in 1959 and studied Foundry Engineering at the Clausthal University of Technology. He pursued a Doctor of Engineering degree in 1991 and worked for different companies in the steel industry including DK Recycling and Roheisen GmbH in Duisburg. Since 2007, Rüdiger Deike is a Full Professor for the Metallurgy of Iron and Steelmaking at the University of Duisburg-Essen. Since 2018, he is also head of the chair of Metal Forming.
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