ROLL PASS
DESIGN - AutoForm Series
Metal Pass has two sets of roll pass design programs available: AutoForm Series
and FreeForm Series. The two sets of roll pass design software
are developed for different purposes.
AutoForm series. The programs in the AutoForm
series are full-automatic, easy-to-use. They require very
little, even no roll pass design experience. The user only
needs to fill in basic operation parameters to the web form,
and the system will run the loop for trial-and-error to design
every parameter for you. Roll pass parameters are verified
during automatic trial-and-error design, until all the
critical factors (fill ratio, aspect ratio, bite angle, etc.)
are in the safe range. Our solid roll pass design knowledge
and sophisticated process models make it possible for this
full-automatic design.
Recent developments include the
addition of Box-Box-Box two-pass sequence for passes from
breakdown, roughing to finishing passes, and the expansion of
the Billet-Box-Square-Oval-Round roughing to flexibly design
large sizes (e.g. 700mm ingot/bloom).
Primary applications
in this series currently consist of:
Round-Oval-Round
(2 Passes, Round-Oval and Oval-Round).
Square-Diamond-Square
(2 Passes, Square-Diamond and Diamond-Square)
Box-Square-Oval-Round
(4-pass train
to roll
from
square
to round)
Box-Oval-Round
(3-pass train
to roll
from
square
to
round)
Round-Box-Square
(2 Passes,
to roll
from
round to
square)
Box-Box
(2 Passes,
Two Box
passes)
Metal Pass LLC also provides
FreeForm series.
This is
a
powerful
series
particularly
designed
for experienced
roll
pass
designer.
It
allows a
roll
pass
designer
to
complete
up to 30
passes
in a
single
project,
from
rough,
intermediate,
pre-finishing
to
finishing
(wire
block)
passes.
User has
freedom
to
specify
design
procedures
for
spread
and
forward
for
every
pass.
User can
either
follow
the
system
determined
spread
factors
calculated
from our
process
models,
or
assign
his own
spread
factor
value.
As a
powerful
feature,
tension
correction
for
spread
and
forward
can be
used if
the user
select
to.
Though
this set
of
programs
apply
for full
range of
roll
pass,
two case
of
application
are in
special
advantageous:
one is
for high
speed
wire
block
(No-Twist
Mill,
etc.)
which is
particularly
challenging
for roll
pass
designer.
Another
is to
study
existing
pass
schedule
for
improvement,
or to
modify
the
existing
pass
schedule
to
create
new one.
Applications
in this
section
consist
of:
(for
multiple passes)
Square-Diamond-Square
(for
multiple
passes)
Related software packages. Usually after pass design is done,
power and force calculation should be performed to check whether the mill
(roll, motor, transmission system, etc.) has sufficient capacity to roll the product(s). For this purpose Metal Pass has developed a set of programs for
mill power and force calculation, as follows:
-
Round-Oval
(1 pass)
-
Oval-Round
(1
pass)
-
Round-Oval-Round
(2 passes)
-
Square-Oval
(1 pass)
-
Box-Box
(1 pass)
-
Square-Diamond
(1 pass)
-
Diamond-Square
(1 pass)
-
Square-Diamond-Square
(2 passes)
-
General
Estimation
(1 passes)
Process models used for the software development.
Design procedures are based on our technical development to combine recent
results worldwide, primarily from Germany, Japan and USA. One of the data
sources, for example, is a 10-year project in Germany in a 4-stand continuous
lab mill (up to 70m/s) with controlled cooling and full measurement
capabilities. Its result was recorded in various reports, which are available
for Metal Pass development. Results from Japanese colleagues (e.g. Shinokura)
were also employed. However, formulation from Shinokura was heavily expanded to
reflect modern rolling practice such as speed (up to over 100 m/s), tension
(especially in the rolling block), roll and stock materials, etc.). A great
amount of field data, primarily from high-speed rolling block, were evaluated
and applied to our roll pass design practice.
-
Metal flow: spread, forward slip, neutral angle, work diameter, tension
correction for spread and forward slip, steel grade effect, free side contour,
etc.
-
Force, torque and power requirements: mean flow stress, roll separating force,
contact area, shape factor, lever arm ratio, torque, power requirement,
effective strain, high speed rolling (e.g. 3000/s), tension effect
-
Roll deformation and strength, mill vibration: elastic deformation of rolls and
stand, stress concentration, roll strength and stand capacity , roll material,
mill vibration
-
Heat transfer and temperature: on roll table, during reheating, during rolling,
water box cooling, free and controlled air cooling, heat transfer coefficient
-
Microstructure formation: dynamic recrystallization, static and metadynamic
recrystallization, grain growth, phase transformation during controlled cooling
during casting (to be completed), rolled product Properties
-
Material data and boundary conditions: flow stress model, friction, specific
heat, E-modulus and poison ratio, thermal conductivity, temperature
conductivity, density, etc.
??
Resources:
- Spread during rolling in grooves.
- On rolling process modeling - mathematical models
- On rolling process modeling - model development
- Forward slip and determination during rolling
- Roll pass technical series
- General considerations on roll pass design
- Spread influence factors
- Introduction to Shinokura spread model
- Shinokura-Li spread model and validation
- Ekelund spread determination
- Introduction to wire rod block and sizing mill
- Roll pass related US patents
- Application notes for metal pass online programs
- Cookies and related setup
- Metal Pass user agreement
-
Development of Model-Intensive
Web-based Rolling Mill
Applications (Tech Paper)
|