Design of Metal Rolling Processes and Control Systems

Rolling mill photoA thin strip steel rolling mill

With an increased demand for thin-gauge metals, quality control during the cold rolling process has become a larger field of focus. Companies in the cold rolling industry have faced issues controlling and maintaining profile consistency during the cold rolling process. To reduce the amount of scrap material created when rolling steel sheets, an accurate and fast design model that predicts stress concentrations is needed. While winding a strip with a non-ideal profile, variations in stress accumulate along the width of the strip and can cause failure. Also, a sensor roll cannot distinguish between winding stresses and deformation stresses caused by the rolling operation. A method is needed to filter out the winding stresses from the sensor measurement. Using applied elasticity theory, an Airy Stress function can be derived and used to predict stresses in the rolling direction as well as shear stress behavior. Simulating the boundary conditions during the winding process allows for analysis of stress distributions and the prediction of certain modes of failure; herringbone, tearing, walk-off, etc. With an accurate model, the desired output stress profile can be adjusted according to the predicted winding stresses, and the correct mill modifications can be performed to arrive at higher quality product.  

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