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Canadian Metallurgical Quarterly, Vol 39, No 3, pp 319-324, 2000 Canadian Institute of Mining, Metallurgy and Petroleum Published by Canadian Institute of Mining, Metallurgy and Petroleum Printed in Canada. All rights reserved

MODIFICATION OF ROLL PASS DESIGN OF LOW PEARLITE, FINE-GRAINED SHEET STEEL USING NUMERICAL MODELING AND PROCESSING MAPS
TAHER EL-BITAR
Central Metallurgical R&D Institute (CMRDI) P.O. Box 87 Helwan, Cairo, Egypt

(Received July 1999; in revised form February 2000)

Abstract The main objective of this pass design is to achieve fine-grained structure with high strength properties and good ductility for 2.0 mm thickness steel sheet on a six stand finishing mill. Numerical modeling is used to evaluate the different rolling parameters while processing maps are used to determine a workability "window" in which dynamic recrystallization must occur. The existing rolling parameters would not lead to a dynamically recrystallized structure. The proposed technique retains the sequence of reduction in thickness at the working temperatures, while it diminishes the rotational speed of the first stand and consequently all the other stands. The first stand is proposed to rotate with 25 rpm at 7.2 s-1 rate of deformation. The final rotational roll speed would be 177 rpm at stand no. 6 with 83.4 s-1 rate of deformation at 850 C. Rolling force and torque needed in the proposed technique are lower than those in the existing ones at most of the passes. The proposed technique saves energy as it reduces the power consumption. Rsum Le principal objectif de cette conception de passe de laminoir est d'obtenir une structure grain fin avec des proprits de rsistance leve et une bonne ductilit pour une tle d'acier d'une paisseur de 2.0 mm, sur un laminoir finisseur six cages. On utilise la modlisation numrique pour valuer les diffrents paramtres de laminage alors qu'on utilise les plans de formage pour dterminer une "fentre" de fabricabilit dans laquelle doit se produire une recristallisation dynamique. Les paramtres actuels de laminage ne peuvent conduire une structure dynamiquement recristallise. La technique propose retient la squence de rduction en paisseur aux tempratures d'opration, tout en diminuant la vitesse de rotation de la premire colonne et, par consquent, de toutes les autres colonnes. On propose que la rotation de la premire colonne soit de 25 rpm, avec un taux de dformation de 7.2 s-1. La vitesse du dernier rouleau serait de 177 rpm la colonne no. 6, avec un taux de dformation de 83.4 s-1, 850 C. La force de laminage et le moment de torsion ncessaires pour la technique propose sont plus bas que ceux qui existent dj pour la plupart des passes. La technique propose conserve l'nergie puisqu'elle rduit la consommation de pouvoir.

INTRODUCTION Mechanical processing is conducted at elevated temperatures in order to impose large strains without the onset of fracture. This process is an essential step in shaping into engineering components. However, the rolled products require not only dimension accuracy but also specified microstructure and mechanical properties. This leads to the controlled roll pass design technique where components can be rolled with controlled microstructure and properties

without defects on a repeatable basis. Roll pass design considers two main aspects; (i) the roll mill and its capability to carry out the job without failure of any of its parts while obtaining the maximum process efficiency and (ii) optimizing properties and required microstructure. With respect to the rolling mill, trial and error techniques are expensive as well as time consuming and may not always lead to a successful solution or optimization. However, in recent years the trial and error techniques have
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been replaced by modeling [1-4]. Modeling of hot rolling provides the necessary information to make changes which improve product quality or reduce the time to market of the new products or processes [5,6]. Moreover, numerical techniques applied to hot flat rolling can evaluate rolling force and torque and power consumption as well at both working temperature and strain rate [7]. From the process point of view, it is useful to classify rolling processes as involving short, medium and long interpass times. Long interpass times are intrinsic in reversing mills, such as plate or roughing mills in which the 10 or more seconds between passes permit the precipitation of carbonitrides in Nb microalloyed steels [8]. Such precipitation inhibits both static and dynamic recrystallization. Truly short interpass times of 15 to 30 ms are intrinsic to the final finishing stands of roll mills. Such interpass times are clearly insufficient for carbonitride precipitation and are generally insufficient for static recrystallization as well [8]. Under these conditions, the strain accumulates from pass to pass leading eventually to the initiation of dynamic recrystallization in the roll gap [3,9]. Numerical Model The numerical model is the main tool for evaluation of the rolling parameters for each pass [7]. It has the following main features; 1. The model must have input with the initial data of the roll mill and process, e.g. working rolls radius (R), coefficient of friction between the working rolls and stock (), number of revolutions per minute of rolls (n) and proposed number of passes (Np). 2. Each pass has to be examined separately as a whole process where both temperature (T) and initial and final thickness (ho, hi) should be supplied into the model. 3. The model computes the rate of deformation (.) at the working temperature according to the formula, [10]; _____ _______ . = (2n/60) . (R/h1) . (1-t)/ t . ln [1/(1-t)] where t is the total strain per pass; t = (ho - h1)/ ho (2)

side of the process are well defined. Each side is divided into sectors of equal angles of contact (). Every sector is considered as a whole rolling process. 6. The normal roll pressure, S(), is evaluated for each sector according to the formula [7]; S() = [f()/h()] + ()[h()/Sin] -0 f ____________________ {1- (2S()/ ())2 (/)2}Cosd Considering a function

(3)

___________________ = [h()/Sin] -0 f {1- (2S()/ ())2 (/)2}Cosd

The value of ranges between 1 and /4. Hence S() = [f()/ h()] + () (4)

where f() is the horizontal force and its value can be evaluated using the model previously published [7,11]. 7. The rolling torque, T, can be consequently calculated as; T= D2/2[- 0 f n S() d + f m S() d (5)

where D is the roll Diameter, n is the neutral angle, [1,7], and m is the whole contact angle. 8. The power consumption per pass (W) is calculated as; W= (.) . T Processing Maps (6)

(1)

4. The model then executes the flow stress-strain equation. 5. The location of the neutral point at the arc of contact is definitely calculated [1,7] and then the entry side and exit
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A hot rolling process is considered as a system which consists of a source of power (roll mill), stores of power (working rolls) and a dissipater of power (the rolled-piece). Energy is generated by the mill and is transmitted to the rolls to store power and transfer it to the workpiece. The workpiece itself dissipates the energy while it undergoes plastic flow to take the shape of the roll gap. On the basis of the above description, an isoefficiency power dissipation contour map is constructed [12] relating the efficiency of power dissipation with temperature and strain rate. Furthermore, Ziegler [13] considered the dynamic material model where one can get the conditions of microstructural stability and through which an instability map can be obtained. These flow instabilities are adiabatic shear bands,

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Temperature, F

flow localization, dynamic strain aging, kink bands, mechanical twinning and flow rotations. The instability map may be added to the power dissipation map to obtain a processing map in which the limits for the unstable flow regime are clearly marked [14]. Processing maps are built at strain rates higher than 10-3 s-1 and temperature field from 0.4 Tm to 0.8 Tm. Metals and alloys often become rate sensitive during high temperature deformation. This requires forming to be carried out within a certain field of the strain rate and temperature (working window) avoiding flow instabilities. Figure 1 represents the processing map of HSLA steels [15]. It is clear that the flow instability region lies between 850 and 1150 C at strain rates higher than 1 s-1. Furthermore, rolling between 1150 and 1200 C with strain rates between 0.001 and 0.02 s-1 leads to wedge cracking. The optimum condition for dynamic recrystallization can be obtained at 1100 C and 0.2 s-1 strain rate [15]. MATERIAL

Log Strain Rate, s-1

Temperature, C

The alloy investigated was a low carbon HSLA steel with the following chemical composition: Table I Chemical Composition of Steel Element C Wt% Si Mn P S Al Nb V Ti

Fig. 1. Processing Map of HSLA Steels at 0.3 Strain, [15]. (Shaded region corresponds to flow instability)

0.12 0.40 1.20 0.030 0.010 0.015 0.09 0.12 0.20

Fig. 2. Quadratic Interpolation of Flow Curves at 10.0 s-1 Strain Rate. CANADIAN METALLURGICAL QUARTERLY

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INITIAL DATA Rolling is carried out on a six stand finishing mill with a 650 mm working roll diameter. The coefficient of friction () is considered as 0.3 over all the passes. The initial thickness of the rolled strip is 16.6 mm at 1100 C and it has to be reduced as; 10.0, 6.2, 4.28, 3.1, 2.34 and 2.0 mm at 850 C at the sixth pass. Neither forward nor back tension is used. The flow stress values are abstracted from that tabulated in reference no. [15]. Linear regression is used to evaluate the values of the flow stress at a definite strain rate. The data of flow curves are stored in a multi-dimensional matrix with coordinates; strain, strain rate, temperature and flow stress. The strain ranges from 0.1 to 0.5, while strain rate ranges from 1.0 to 100 S-1. The temperature coordinate ranges from 850 to 1200 C [15]. Figure 2 shows a quadratic interpolation of flow curves at 10.0 s-1 strain rate.

nique always has lower values as the initial rotational speed is lower than that currently used. This is reflected by the values of the rate of deformation as presented in Figure 4. Obviously the rate of deformation values at the existing passes always lies in the flow instability region which may led to adiabatic shear banded structure. By contrast, the proposed technique would create a mostly dynamic recrystallized structure as the majority of values are going through the workability window and would avoid both the flow instability region and wedge cracking ones [15]. Figure 5 represents the flow curves at the temperatures and strain rates for both the existing passes and proposed ones. It is clear that the flow stresses of the proposed technique are mostly lower than those at the existing state at all passes which would be beneficial and have positive effects on the other rolling parameters.

Fig. 3. Rolls Rotational Speed at Different Passes Temperature.

PROCESSING OF DATA AND MODIFICATION Figure 3 shows the roll rotational speed at different pass temperatures for both the existing and proposed techniques. The rotational speed generally increases from pass to pass as the deformation progresses. However, the proposed tech-

Fig. 4. Rate of Deformation at Different Passes for the Existing and Proposed Techniques. CANADIAN METALLURGICAL QUARTERLY

Fig. 5. Flow Curves at Different Rolling Temperatures and Deformation Rates of Existing Passes (top) and Proposed Ones (bottom).

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Fig. 6. Specific Rolling Force Variation with the Rolling Temperature.

Fig. 8. Specific Power Consumption at Different Pass Temperatures for Both the Existing and Proposed Cases.

To realize the proposed technique, it is important to look at the rolling force and torque as well as the power consumption. Figure 6 represents the specific rolling force (Rolling force / amount of deformation in pass) variation with the working (rolling) temperature for the existing and proposed techniques. Both curves have two peaks and a trough in between reflecting the strain hardening and softening phenomenon which occurred in steel during deformation by hot rolling, [3, 9, 16]. Furthermore, it is clear that the proposed technique decreases the rolling force needed which is more beneficial to the roll mill. Figure 7 is a correlation between the specific rolling torque and the working temperature for the existing and proposed passes. The rolling torque for both cases decreases continuously as the steel passes from one stand to another due to the continuous increase of deformation rate and consequently the rotational speed [6, 11] (Fig. 3). From the economical point of view, the proposed process diminishes the power consumption over all the passes. This is clear from Figure 8, which shows the specific power consumption at different passes and at different temperatures for both the existing and proposed cases. By contrast the productivity of the existing technology reaches 14.97 meter steel sheet / sec. while productivity reaches 6.04 m/sec. in the proposed technique. Furthermore, in the proposed technique it is necessary to carry out fast cooling

after the last pass to 700 C to avoid grain coarsening by static grain growth [6, 8]. However, the existing production is an ordinary low carbon-low strength steel, but the proposed production is low carbon (low pearlite content) and fine-grained steel with highly isotropic and mechanical properties with a higher price and better demand.

CONCLUSIONS 1. Both numerical modeling and processing maps are used to design roll passes that can lead to dynamic recrystallized structure low carbon HSLA steels by changing the rotational speed of passes and consequently controlling the rate of deformation. 2. Rolling forces needed are lower in the proposed technique than those in the existing ones at most of the passes. 3. Rolling torque in the proposed case is lower especially at the first pass where high torque value is needed. 4. The proposed technique saves energy as it reduces the power consumption. However, productivity is negatively affected.

Fig. 7. Correlation between the Specific Rolling Torque and Working Temperature for the Existing and Proposed Passes. CANADIAN METALLURGICAL QUARTERLY

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REFERENCES 1. T. El-Bitar, "A Computer Program for the Calculation of Roll Force and Torque with Strip Tension in Cold Rolling.", Iron and Steelmaker, 87-96, May 1993 & Transactions of Iron and Steel Society, vol. 15, 1994. Y. Prasad, "Modeling of Dynamic Material Behavior in Hot Deformation: Forging of Ti-6242", Met. Trans. A, 15A, Oct. 1984, 1883-1892. F. Siciliano, K. Minami, T. Maccagno, and J. Jonas, "Mathematical Modeling of the Mean Flow Stress, Fractional Softening and Grain Size during the Hot Strip Rolling of C-Mn Steels, ISIJ Intr., 36, 12, 1996, 1500-1506. A. Halal and B. Kaftanoglu, "Computer-Aided Modeling of Hot and Cold Rolling of Flat Strip", Int. Conf. on Computers in Engineering, Las Vegas, Nevada, 1984, 120-126. S. Lundberg, "Roll Pass Design - The Key Function in Control of Shape, Dimension and Mechanical Properties of Hot Rolled Products", 1 st. European Rolling Conf. (HUNGAROLLING 96), vol. I, 4-6 Sep. 1996, Balatonszeplak, Hungary. H. McQueen and J. Jonas, "Metal Forming - Interrelation between Theory and Practice", A. L. Hoffmanner ed. Plenum Press, New York, NY, 1971. T. El-Bitar, "Constitutive Modeling and Analysis of Hot Flat Rolling", 1st European Rolling Conf. (HUNGAROLLING 96), vol. I, 4-6 Sep. 1996, Balatonszeplak, Hungary. G. Li, T. Maccagno, D. Bai, and J. Jonas, "Effect of Initial Grain Size on the Static Recrystallization Kinetics of Nb Microalloyed Steels", ISIJ, 36, 12, 1996, 1479-1485. F. Siciliano, "Mathematical Modeling of the Hot Strip Rolling of Nb Microalloyed Steels" Ph. D. Thesis, McGill University, Montreal, Canada, Feb. 1999.

15. Y. Prasad and S. Sasidhara, "Hot Working Guide - A Compendium of Processing Maps", ASM International, Metals Park, OH 44073-002, 1997, 337-339. 16. K. Minami, F. Siciliano, T. Maccagno and J. Jonas, "Mathematical Modeling of Mean Flow Stress during the Hot Strip Rolling of Nb Steels, ISIJ Intr., 36, 12, 1996, 15071515.

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10. R. Sims, "Calculation of Roll Force and Torque in Hot Rolling Mills", Proc. Inst. Mech. Engrs., 166, 1952, 75-81. 11. T. El-Bitar, "Valuation of Rolling Force and Torque of Steel through Modeling with the Aid of Hot Compression Tests", 7th International Conference on Force, Mass and Torque Measurements, Sep. 14-18, 1998, 403-407, Korea Research Institute of Standards and Science (KRISS), Taejon, Republic of Korea. 12. L. E. Malvern, "Introduction to the Mechanics of Continuous Medium", Prentice-Hall, Eaglewood Cliffs, NJ, 1969, 197. 13. H. Ziegler, "Progress in Solid Mechanics", Vol. 4, Eds. John Wiley and Sons, New York, 1963, 93. 14. R. Rishi, "Development of Processing Map for Use in Warmforming and Hot-forming Processes", Met. Trans. A, 12A, June 1981, 1089-1097.

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