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ROLL PASS
DESIGN - FreeForm Series
This is the FreeForm series of our roll design systems. It
provides full freedom of trial-and-error design for the pass and
groove parameters. For every trial, the system calculates spread, forward slip,
roll RPM, and all other critical parameters.
This is a powerful series particularly designed
for experienced roll pass designers. It allows a roll pass
designer to complete a large number of passes in a single project, from
roughing, intermediate, pre-finishing to finishing (wire block)
passes. User has freedom to specify design procedures for
spread and forward for every pass. User can either follow the
system determined spread factors calculated from our process
models, or assign his own spread factor values. As a powerful
feature, tension correction for spread and forward slip can be used
if the user select to. Though this set of programs apply for
full range of roll pass, two cases of applications are in
special advantage: one is for high speed wire block
(No-Twist Mill, etc.) which is particularly challenging for
roll pass designer. Another is to study existing pass schedules
for improvement, or to modify the existing pass schedules to
create new ones.
Applications in this section consist of:
-
Round-Oval-Round
(for
multiple passes)
-
Square-Diamond-Square
(for
multiple
passes)
Metal Pass LLC also provides
AutoForm series
to allow full-automatic roll pass design, in which you only need to fill out
the form with basic operational parameters. Applications in this series
consist of:
??
Round-Oval-Round
(2 Passes, Round-Oval and Oval-Round).
Square-Diamond-Square
(2 Passes, Square-Diamond and Diamond-Square)
Billet-Box-Square-Oval-Round (4-pass roughing
train)
Related software packages. Usually after pass design is done,
power and force calculation should be performed to check whether the mill
(roll, motor, transmission system, etc.) is strong enough to roll the
product(s). For this purpose Metal Pass has developed a set of programs for
mill power and force calculation, as follows:
-
Round-Oval
(1 pass)
-
Oval-Round
(1
pass)
-
Round-Oval-Round
(2 passes)
-
Square-Oval
(1 pass)
-
Box-Box
(1 pass)
-
Square-Diamond
(1 pass)
-
Diamond-Square
(1 pass)
-
Square-Diamond-Square
(2 passes)
-
General
Estimation
(1 passes)
Process models used for the software development.
Design procedures are based on our technical development to combine recent
results worldwide, primarily from Germany, Japan and USA. One of the data
sources, for example, is a 10-year project in Germany in a 4-stand continuous
lab mill (up to 70m/s) with controlled cooling and full measurement
capabilities. Its result was recorded in various reports, which are available
for Metal Pass development. Results from Japanese colleagues (e.g. Shinokura)
were also employed. However, formulation from Shinokura was heavily expanded to
reflect modern rolling practice such as speed (up to over 100 m/s), tension
(especially in the rolling block), roll and stock materials, etc.). A great
number of field data, primarily from high-speed rolling block, were evaluated
and applied to our roll pass design practice.
- Metal flow: spread, forward slip, neutral angle, work diameter, tension
correction for spread and forward slip, steel grade effect, free side contour,
etc.
- Force, torque and power requirements: mean flow stress, roll separating force,
contact area, shape factor, lever arm ratio, torque, power requirement,
effective strain, high speed rolling (e.g. 3000/s), tension effect
- Roll deformation and strength, mill vibration: elastic deformation of rolls and
stand, stress concentration, roll strength and stand capacity , roll material,
mill vibration
- Heat transfer and temperature: on roll table, during reheating, during rolling,
water box cooling, free and controlled air cooling, heat transfer coefficient
- Microstructure formation: dynamic recrystallization, static and metadynamic
recrystallization, grain growth, phase transformation during controlled cooling
and during casting (to be completed), rolled product Properties
- Material data and boundary conditions: flow stress model, friction, specific
heat, E-modulus and poison ratio, thermal conductivity, temperature
conductivity, density, etc.
Resources:
- Spread during rolling in grooves.
- On rolling process modeling - mathematical models
- On rolling process modeling - model development
- Forward slip and determination during rolling
- Roll pass technical series
- General considerations on roll pass design
- Spread influence factors
- Introduction to Shinokura spread model
- Shinokura-Li spread model and validation
- Ekelund spread determination
- Introduction to wire rod block and sizing mill
- Roll pass related US patents
- Application notes for metal pass online programs
- Cookies and related setup
- Metal Pass user agreement
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Development of Model-Intensive
Web-based Rolling Mill
Applications (Tech Paper)
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