Advanced Materials Research Vol. 898

Abstract: The corrugated waist rail has been successfully rolled in the Mill Research Institute of Yanshan University. It is necessary to conduct a comparative study on the mechanical properties of this special kind of rail with that of the ordinary rail. ANSYS/LS-DYNA, the finite element code, is used to simulate the contact behavior of wheel and rail. The study aims to investigate the influences of axle and lateral load on the stresses and displacement of the rail. It draws a conclusion that the mechanical properties of the corrugated waist rail is superior to that of the ordinary rail. It also provides a method and useful data for the further research on fatigue and wear of corrugated waist rail.

Abstract: According to the production data of a rolling H-beam factory, the FE model of hot continuous rolling process of H-beam is built. The rolling process of H-beams is simulated by explicit dynamic FEM, and the influence of deformation parameters on the spread of rolling piece is analyzed. The simulation results show that the flange width, elongation ratio between flange and web and flange thickness are the major influencing factors on the spread of rolling piece.

Abstract: The housing fillet of universal mill affects the strengthen and stiffness of mill. It is necessary to optimize the housing fillet. In this paper, the simulated annealing algorithm (SA) combined with finite element method (FEM) , a new kind of structural optimization method is established. MATLAB language is used to compile the program combined the SA with FEM to optimize housing fillet of universal mill. Compared with the zero order and first order optimization method of ANSYS program, the result of this optimal method is better.

Abstract: Complex shape of H-beam section and uneven elimination of heat on the section result in too big temperature difference between web and flange. At the same time,as the roller cooling water forms tank on H-beam web, the section temperature difference further increases. Based on finite element analysis software DEFORM-3D, the FEM model of finished product size of H194×150×6×9 is established. Thermo-mechanical coupled method is adopted to simulate the rolling process of H-beam. The cooling water influence on section temperature distribution, equivalent stress and strain distribution is analyzed. The section temperature change characteristic are studied to provide reference for further research.

Abstract: Y-Type rolling mill with three roller is a new kind of wire mill. Because of its unique advantage, It is very important to optimize structure. Roller is important part of the rolling mill, whose size effects the strength, stiffness, as well as the rolling piece quality and service life of the rolling mill. Therefore, It is important to optimize the roller structure dimension of Y-type mill.A new structure optimizing method is set up combined the modified genetic algorithms with finite element method.This method can solve multi-objective problems with more complex constraints in the engineering. Compared with the zero order method and first order method companied with ANSYS, the result of this optimizing method is better. This method can solve multi-objective problems with more complex constraints in the engineering, providing a new and effective means for the engineering problems.

Abstract: The rolling process of corrugated waist rail is simulated by explicit dynamic FEM module ANSYS/LS-DYNA. The distribution of residual stress of the rolled piece after rolling is analyzed, The influence of rolling velocity, the reduction ratio, and rolling temperature on the residual stress are analyzed. According to the result of simulation, it is helpful to the actual production.

Abstract: Controlled cooling of H-beam after rolling, can change the microstructure consituent,improve the strength and improve the general mechanical property and service performance. According to actual product, the rational thermal boundary condition adopted, three dimensional FEM model is established. Spray cooling is used. Transient temperature field and stress field is simulated by the FEM software ANSYS/Multiphysics when H-beam is cooled. The four kinds of cooling scheme are designed. Through analysis of the relation of temperature field with stress field, the main reason of producing residual thermal stress is the section temperature difference in the cooling process of H-beam after rolling.

Abstract: Because of the residual stress of H-beam after hot rolling, the service performance of H-beam is seriously impacted. it is necessary to reduce the residual stress by controlled rolling and cooling process. In this paper, a continuous rolling model of finish product of H200 x 200 x 8 x 12 is set up. The continuous rolling process of H-beam was simulated using the large finite element software ANSYS/LS-DYNA. The effect of non-uniform elongation of web with flange and section temperature difference on the residual stress are analyzed. Through metallographic observations, the vary microstructure of rolling piece with residual stress and with no residual stress is analyzed. As can be seen from the finite element analysis and the experimental results, reasonable elongation of flange and web and controlling cooling speed to decrease the sectional temperature difference can reduce the residual stress of H-beam.

Abstract: The corrugated web rail is a special kind of rail structure. Horizontal roller of rolling the corrugated web rail is named as tooth-shaped roller because its shape is close to straight tooth gear. The profile curve of tooth-shaped roller has great influence on the finish product quality , the rolling process and the rolling force of the corrugated web. In this paper, profile curve of tooth-shaped roller of rolling corrugated web rail was designed. FEM model of rolling corrugated web rail was established and the rolling process was simulated by the software ANSYS/LS-DYNA. In the condition of the same reduction and the same rolling speed, the rolling force was compared of experiment profile curve with the designed profile curve. According to the analysis results, the rolling force of the designed profile curve is significantly smaller than that of experimental profile curve. Therefore, it is necessary to optimize profile curve of the tooth-shaped roller to decrease the rolling force.

Abstract: The three-dimensional models of rolling are established with Pro/E. Based on the finite element analysis software ANSYS/LS-DYNA, the procedure of bar tandem rolling is simulated. The nephograms of stress and strain of bar deformed area and the curve of roll force during rolling are obtained. Compared the result with the other result which comes from optimization, the precision of calculation will be verified.