Numerical Analysis of Multi-Pass H-Beam Hot Rolling Processing

Abstract:

Hot rolling is a basic metal forming technique that is used to transform preformed shape into final products of forms more suitable for further processing. As the hot stock progresses through the forming surfaces, the shape eventually reaches a constant state. With the assumption of forming process has reached steady-state condition, a simulation technique based on elements re-meshes has been constructed to analyze the H-beam metal hot roll process. The technique includes the following approaches: the solution was halted as soon as the steady-state criteria were met, and the plane of elements, which first satisfied the steady-state criteria were written to database, SSES for short; a two-dimensional model was created to model the hot stock cooling between the two roll passes and a geometric part was generated and meshed with quadrilateral elements to transfer the nodes temperatures; a new three-dimensional model extruded from the two-dimensional model was constructed to model the next roll pass with the transfer of nodes temperatures and element integration points equivalent plastic strain(PEEQ), identifying the plastic deformation extent for the classical metal plasticity models, from the new two-dimensional model and the first three-dimensional model respectively. Gleeble-1500 tester is used to get the true stress and true plastic strain data for modeling the yield behavior of material Q235. The effectiveness of the simulation technique has been proved by a simulation of 11-pass H-beam rolling process.

• Periodical: Applied Mechanics and Materials (Volumes 190-191)
• Pages: 385-389
• DOI: https://doi.org/10.4028/www.scientific.net/AMM.190-191.385
• Online since: July 2012
• Authors: Qing Qiang He, Jia Sun, Jun You Zhao, Bao Min Yuan, Li Jian Xu
• Keywords: H-Beam, Microstructure Evolution, Multi-Pass Hot Rolling, Numerical Analysis

References

[1] A.A. Milenin, Simulation of metal forming during multi-pass rolling of shape bars, Journal of Materials Processing Technology 153–154 (2004) 108–114.

DOI: 10.1016/j.jmatprotec.2004.04.320

[2] Z. Pater, Theoretical and experimental analysis of cross wedge rolling process,International Journal of Machine Tools & Manufacture 40 (2000) 49–63.

DOI: 10.1016/s0890-6955(99)00047-4

[3] L.M. Galantucci, Thermo-mechanical simulation of a rolling process with an FEM approach, Journal of Materials Processing Technology 92–93 (1999) 494–501.

DOI: 10.1016/s0924-0136(99)00242-3

[4] Migule A.Cavaliere, Finite element analysis of steel rolling processes, Computers and Structures 79(2001) 2075-2089.

DOI: 10.1016/s0045-7949(01)00055-4

[5] K. Komori, Simulation of deformation and temperature in multi-pass caliber rolling, Journal of Materials Processing Technology 71 (1997) 329–336.

DOI: 10.1016/s0924-0136(97)00094-0

[6] Y.S. Kang, D.Y. Yang, A three dimensional finite element analysis of hot extrusion through square dies—automatic remeshing technique with modular concept, Eng. Comput. 14 (1997) 926–948.

DOI: 10.1108/02644409710192308

[7] J. Zhu, M. Gotoh, An automated process for 3D hexahedral mesh regeneration in metal forming, Comput. Mech. 24 (1999) 373–385.

DOI: 10.1007/s004660050458

[8] M.L. Alves, Finite element remeshing in metal forming using hexahedral elements, Journal of Materials Processing Technology 141 (2003) 395–403.

DOI: 10.1016/s0924-0136(03)00388-1

[9] A.O. Cifuentes, A. Kalbag, A performance study of tetrahedral and hexahedral elements in 3-D finite element structural analysis, FiniteElements Anal. Des. 12 (1992) 313–318.

DOI: 10.1016/0168-874x(92)90040-j

[10] T. M. Maccagno. J. J. Jonas, P. D. Hodgson. Spreadsheet Modeling of Grain Size Evolution during Rod Rolling [J], ISIJ International, 1996, 36 (6): 720-728.

DOI: 10.2355/isijinternational.36.720

[11] F. Siciliano, K. Minami, T. M. Maccagno, J. J. Jonas. Mathematical Modeling of Mean Flow Stress, Fractional Softening and Grain Size during the Hot Strip Rolling of C-Mn-Steels[J], ISIJ International, 1996, 36(12): 1500-1506.

DOI: 10.2355/isijinternational.36.1500

[12] K.P. Rao, Y.K.D.V. Prasad, E.B. Hawbolt. Hot Deformation Studies on Low-Carbon Steel: Part 1-Flow Curves and the Constitutive Relationship [J]. Journal of Materials Processing Technology, 1996, 56:897-907.

DOI: 10.1016/0924-0136(95)01902-2

[13] K.P. Rao, Y.K.D.V. Prasad, E.B. Hawbolt. Hot Deformation Studies on Low-Carbon Steel: Part 2-An Algorithm for the Flow Stress Determination under Varying Process Conditions [J]. Journal of Materials Processing Technology, 1996, 56:908-917.

DOI: 10.1016/0924-0136(95)01903-0

[14] F. G. Caballero, C. Capdevila, C. García de andrés. Modeling of Kinetics of Austenite Formation in Steels with Different Initial Microstructures [J], ISIJ International, 2001, 41(10): 1093-1102.

DOI: 10.2355/isijinternational.41.1093

[15] J.M. Cabrera, J. Ponce, J.M. Prado. Modeling thermomechanical processing of austenite [J]. Journal of Materials Processing Technology, 2003, 143: 403-409.

DOI: 10.1016/s0924-0136(03)00441-2

[16] P.D. Hodgson. Microstructure modeling for property prediction and control [J]. Journal of Materials Processing Technology, 1996, 60:27-33.

[17] J. Lin, T.A. Dean. Modeling of microstructure evolution in hot forming using unified constitutive equations [J]. Journal of Materials Processing Technology, 2005, 167:354-362.

DOI: 10.1016/j.jmatprotec.2005.06.026

[18] Y. Liu, J. Lin. Modeling of micro-structural evolution in multi-pass hot rolling [J]. Journal of Materials Processing Technology, 2003, 144:723-728.

[19] N. Bontcheva, G. Petzov .Total simulation model of the thermo-mechanical process [J]. Shape rolling of steel rods Computational Materials Science, 2005, 34:377-388.

DOI: 10.1016/j.commatsci.2005.01.009

[20] M. Glowacki. The mathematical modeling of thermo-mechanical processing of steel during multi-pass shape rolling [J]. Journal of Materials Processing Technology, 2005, 168:336-343.

DOI: 10.1016/j.jmatprotec.2004.12.007