Force And Energy Requirements In Material Processing

In Smart Manufacturing and intelligent equipment, the core parameter requirements are the force and energy in the processing process. In industrial production, the calculation of force and energy demand of machining process needs to be customized. Although the conventional measurement can measure the required power loss, these do not represent the real power demand of the processing process, and there is at least one coefficient difference between them.

1. Model Advantages Of The Team

Our team has developed more than 100 sets of production models in emerging industries and more than 100 sets of production models in traditional industries in the past decades, which has the advantage of developing the power and energy requirements of specific process on site, such as

- Extrusion, drawing, forging, rolling, stamping, spinning, etc
- Slurry mixing, coating, baking, rolling, slitting, winding, etc
- Production process of various high-end materials
- Production process of various new energy industry materials
- Production process of various automobile parts
- Etc.

2. Relevant Production Cases

Considering the complexity of the model, the following example is the force and energy demand of profile during high-speed machining (100M / s) between steel roll passes.

The application software of rolling mill load is specially developed for rolling mill design / operation engineers to calculate rolling force, rolling torque and power. Generally, when a new rolling process is applied to materials with higher reduction, lower temperature, higher speed or higher strength, load calculation is necessary for an existing rolling mill. This is to ensure that the rolling force and torque do not exceed the bearing capacity of the equipment. When building a new plant, the selection of engine, the decision of plant scale and the design of transmission system are all based on the load calculation of equipment.

The application software for pass sequences in this section includes:

• Round-Oval (1 pass)

• Oval-Round (1 pass)

• Round-Oval-Round (2 passes)

• Square-Round (1 pass)

• Box to box (1 pass)

• Square-Diamont (1 pass)

• Diamond-Square (1 pass)

• Square-Diamont-Square (2 passes)

• General pass estimation (1 pass)

The application software of this rolling mill is based on our advanced rolling mill process model, especially those models that determine the requirements of rolling force, torque and power. Based on the experimental results of a large number of rolling mills in the United States and Germany in the past 30 years, the model has been developed and continuously improved. In order to obtain high prediction accuracy, every detail involved should be carefully determined. for example

• Projected contact area. The elementary slab method, together with the spread and pass sequence, is used to construct the imaginary contour. For some passes, the use of the contact surface model is based on the experimental results of the shape of the contact surface in different pass sequences.  

• Average flow stress. The distribution of strain along the length range is from 0 at the inlet to the maximum value of strain at the outlet (pass strain). Average strain is used to achieve high accuracy. The rheological stress model is specially formulated for the strain rate in the range of 0.05-500 / S (applicable to 3000 / s); Therefore, the rolling speed of modern model is more than 100 meters / second.

• Shape factor (Q factor). This coefficient includes pass sequence, entering billet shape and contact surface, etc. The shape factor model is a ten-year study of the rolling process on a four stand high-speed tandem mill (speed up to more than 70m / s) in those developed countries.

• Lever arm ratio. During the torque calculation, in addition to accurately calculating the rolling force, an experimental model is established for each force arm ratio in each pass.

The development of this system is based on a large number of production measured results. The software and model have been verified and further optimized by a large number of field projects, such as POSCO project in Korea. South Korea POSCO project needs to meet nine mutually restrictive conditions at the same time. Only by using high-precision software can it meet many requirements at the same time.

Software/APP

  Achievement, T- field, AutoForm, FreeForm, Power
  Simulation, Flow stress, Hi-T property, Low-T property

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