Level 2 Model Draft
Scheduling Improvement
Level 2 Draft Scheduling
Issues
Rolling mill
draft scheduling is one of the primary task for the Level 2
model.
Level 2 model
is an expended
roll pass design program for flat rolling (currently the shape
rolling roll pass schedules are primarily generated by design
engineers rather than Level 2 models). The requirements for
the draft scheduling exist at least in three areas: (1)
targeted finish size (width, high and length) should be
achieved within the dimension tolerances; (2) flatness of the
rolled strip/plate should be sufficiently high; straightness
of the rolled product should also be good; and (3) rolled
steel properties, such as tensile strength and yield strength,
etc. should satisfy the property requirement. All of the
above-mentioned requirements, except the straightness (Camber
issue), are directly or indirectly related to the draft
scheduling.
Draft scheduling Constrains
Flat rolling
draft scheduling is under many constrains, such as equipment
capacity, productivity and product quality. For roughing
passes,
it is aimed to press
steel as hard as
possible in order to
reach high productivity, so the restrain is primarily the
equipment capacity such as the maximum force and maximum
torque of the equipment. Equipment should not be damaged and
the roll should not be broken. Roughing passes are also with
some requirements for width target. In the finishing passes,
two contradictory factors should be compromised for a given
accuracy of the Level 2 model in order to achieve the proper
product quality. On one hand a low draft is helpful to achieve
better flatness (low levels of the center buckle and edge
wave) because a high draft is more liable to a draft
difference between the width center and width sides. On the
other hand, a high draft (often accompanied with a low
temperature) can increase mechanical properties for a given
steel grade; or for given requirements of the rolled steel
properties a lower-cost grade can be used to fulfill an order
and to save large amount of money. For a given accuracy of the
Level 2 model those two contradictory factors have to be
balanced. However, with a higher accuracy of the Level 2
model, a higher draft and lower temperature can be used while
the flatness of the rolled steel remains good. The high
quality Level 2 model makes it
possible to schedule a lower-cost grade than regular one for a product order,
and/or to increase the yield and productivity. Usually in the
finishing pass, the force and torque limits are not a
constrain factor for the draft scheduling.
Roll deformation and
temperature accuracy issues
Flat rolling
draft scheduling is primarily based on force prediction
together with force induced roll deformation (e.g. deflection,
flattening), etc.
During the rolling, due to the
existence of the roll separating force, there must be the roll
deformations such as the roll deflection and roll flattening.
Due to the high
requirement for the flatness of the rolled steel, roll crown
(both thermal crown and mechanical crown), roll deflection and
roll flattening, etc. have to be accurately determined.
Failure to achieve so would cause center buckle (if the draft
in the middle is too high) or edge wave (while the draft in
the two edges is too high), etc.
One of the key function for the Level 2 model is to select the
needed roll deflection, etc. for a given roll crown, which is
also calculated by the Level 2 model with the initial
mechanical crown, roll thermal crown and roll wear, etc. If
the Level 2 model cannot accurately determine those roll
deformations and the roll crowns, for whatever reason (force
inaccuracy, poor deformation model or poor crown model, etc.),
the deformation over the steel strip/plate width is not equal.
If the difference is over a certain limit, defects such as
center bucket or edge wave would be caused. See the discussion
on the cause
center buckle and edge wave in the
Significance of Accurate Level 2 Force Prediction section.
How we
Improve your Draft
Schedule
In the first step we would improve
your model prediction accuracy for the roll separating force
and temperature. See related documents such as:
For the roughing passes, we would
carefully check whether the roll separating force and rolling
torque are over the equipment's maximum values, if not,
whether there is room to increase draft in order to achieve
higher productivity. Mean while, geometry deformation will also be carefully check to eliminated
potential problems (e.g. fish tail). We would apply high draft
for certain passes also for the purpose of the finish product
properties.
In the finish
passes, the roll deflection, roll flattening, roll crown,
thermal crown, mechanical crown, etc. will be carefully
determined in order to achieve the equal draft over the strip
width. We improve the Level 2 model by applying our rolling
process models in predicting each of the above-mentioned roll
deformation and roll crowns.
We may apply our mathematical
model to quantitatively predict certain defects such as center
buckle and edge wave.
Many Level 2 model use linear
algorithm to perform draft scheduling. If you prefer, we may
introduce nonlinear algorithm for your draft scheduling.
However, we would suggest that you improve your model
predictions for the force and temperature first, especially
the force prediction model.
Our accurate model would increase
your potential to reduce your slab cost in fulfilling a given
product order. This would save you large amount of money
because the slab cost is truly the primary part (about
50-60%) of your expense.
Metal Data Resources on
Level 2 Model Improvement
Metal
Data
Work List on Level 2 and Mill Modeling
Metal Data Research Reports
-
Automation (L2/L3/L1)
-
Modeling
-
Rolling & Roll Pass
-
Metallurgy & Materials
-
Metal Working
Technical papers published
in the February and March of
2008. Those
publications are primarily
on Level 2, Level 2 model
and process automation.
List of
available process models for steel mill
developed
by Metal
Data
(Dr. Benjamin Li)
Metal Data
software applications
List of
computer
classes
completed
by Dr.
Benjamin
Li
Metal
Data IT
&
Software
Technology
Resources
OpenVMS User Guide Created
for Steel Mill Systems
(500 Pages)
See the profile for the primary consultant
Dr. Benjamin Li. You may also view our
company and personnel profiles. Please contact
us via email
bli68@qq.com or by phone
(0086)
13400064848 for top quality consulting
services.
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