Sharif Digital Repository

Prediction of temperature distribution within work-rolls during the hot strip rolling process is of great importance to mill designers because of the significant role it plays in the product's dimensional accuracy and roll life. The present article employs the unsteady state heat transfer equation with time-dependent boundary conditions, as well as a two-dimensional finite element method, to determine work-roll temperature variations during continuous hot strip rolling. To achieve an accurate temperature field, the authors consider the effects of different factors, including work-roll and metal thermal relationship, idling work-roll revolutions, and the effects of various process parameters... 

A mathematical model was developed to assess thermomechanical behavior of work rolls during warm rolling processes. A combined finite element analysis-slab method was first developed to determine thermal and mechanical responses of the strip being rolled under steady-state conditions, and then, the calculated roll pressure and temperature field were utilized as the governing boundary conditions for the thermomechanical problem of the work roll. Finally, the thermomechanical stresses within the work rolls were predicted by a thermoelastic finite element approach. The results of the model indicate that, in warm strip rolling, thermal and mechanical stresses developed in the work rolls are... 

The production of an aluminum-clad steel sheet by the cold rolling process is a more efficient and economical approach compared with the other types of processes utilized for the production of such sheets. In this process, high plastic deformation of two metals, aluminum and steel, is necessary to create the cold bonding between the intermediate surfaces. Therefore, the work-hardened sheet must be annealed in order to obtain a high formability. Heat treatment of the sheet is, however, difficult due to the formation of a brittle intermetallic compound of aluminum and iron at the interface between the layers during heat treatment. In this investigation, the formability of these sheets was... 

Predicting temperature distributions in the work-rolls during the hot slab rolling process is of great importance to mill designers. This is because the temperature distribution and the dimensional accuracy of the slab being rolled are both dependent on the work-roll temperature. In addition, the life of the roll is also a function of its own temperature distribution. In this paper, the unsteady state heat transfer equations with time dependent boundary conditions are coupled with a two-dimensional finite element method to predict the work-roll temperature distribution during the continuous hot slab rolling process. To achieve an accurate temperature field, the effects of various factors... 

In this study a slab analysis is developed to predict the rolling pressure distribution and rolling force in the wire flat rolling process. In the slab analysis the variations of width of contact area between the rolls and wire during rolling is considered. Two differential equations are derived and solved using a modified Eulerian numerical method. The effects of friction coefficient, reduction in height and yield stress of wire on the rolling pressure distribution and rolling force are assessed. It is found that in the flat rolling of wire, there exists a maximum in the pressure distribution similar to that of the strip rolling process. Also, the effects of friction coefficient, reduction... 

Temperature variations of work-rolls in the process of hot rolling of slabs were analyzed by solving heat conduction equation with time-dependent boundary conditions. The Raylieght-Ritz and the finite-element methods were employed to solve the governing equation. To improve the accuracy, the thermal relationship between rolling metal and work-rolls was taken into account as well as the effects of different parameters such as interface heat transfer coefficient, rolling speed, and slab initial temperature were considered in the calculations. To verify the employed model, a comparison was made between the predicted and the recorded time-temperature history and good agreement was observed.... 

In this research the deformation of wire in flat rolling process has been investigated. A theoretical relationship has been developed to relate the reduction in height of wire to the width of contact area between the rolls and wire. This relationship depicts that the width of contact area is proportional to square root of reduction in height of wire. Using that relationship the width of contact area for wires of different diameter have been calculated and compared with the appropriate experimental data after flat rolling. Also, a relationship is developed to assess the effect of reduction in height of wire on the lateral spread in wire flat rolling process. Moreover, the effect of material... 

Optimized conditions of hot and cold rolling followed by annealing can result in a balance between recrystallization and rolling textures in order to reduce the planar anisotropy of brass sheets. In this work, the effect of finish rolling temperature, cold reduction and annealing temperature on texture development has been investigated. It is shown that uniform deformation at higher finishing temperature is responsible of formation of a severe Cube and G texture components. In contrast, mechanical twinnings are widely formed at low finishing temperatures. There is also a direct relation between the intensity of Cube component and the amount of cold reduction  

Detection of rolling bearing faults by vibration analysis is an important part of condition monitoring programs. In this paper a new method for detection of bearing defects based on a new concept of local surface roughness, is proposed. When a defect in the bearing grows then roughness of the defective surface increases and measurement of the roughness can be a good indicator of the bearing defect. In this paper a method of indirectly measuring surface roughness by using vibration signal is introduced. Several attached examples including both numerically simulated signals and actual experimental data show the effectiveness of the new, easy-to-implement method  

A pair of bodies rolling on each other is an interesting example of nonholonomic systems in control theory. There is a geometric condition equivalent to the rolling constraint which enables us to generalize the rolling motions for any two-dimensional Riemannian manifolds. This system has a five-dimensional phase space. In order to study the controllability of the rolling surfaces, we lift the system to a six-dimensional space and show that the lifted system is controllable unless the two surfaces have isometric universal covering spaces. In the non-controllable case there are some three-dimensional orbits each of which corresponds to an isometry of the universal covering spaces  

In the present study a laboratory flat rolling machine is utilized to assess the deformation behavior of low and high carbon steel wires in wire flat rolling process. The effects of friction coefficient, rolling reduction and roll speed on rolling force and deformation behavior of the wires are experimentally investigated. It is found that the roll speed affects considerably the rolling force but a negligible effect on deformation behavior. It is noted that by increasing the roll speed, the rolling force may decrease or increase depending on the magnitude of the roll speed. Also, the deformation behavior of the wires in flat rolling is formulated. A relationship is developed for calculating... 

In this study, a mathematical model is presented for predicting temperature and velocity fields together with dynamic and static microstructural changes during hot rod rolling utilizing a finite element model. For doing so, heat transfer and plasticity equations are coupled with the additivity rule and Avrami rate-equation to consider the dynamic and static microstructural changes as well as to evaluate the effects of temperature and strain rate variations on flow stress of rolling metal. To verify the results of the employed model, a comparison is made between the measured surface temperature during rod rolling and the predicted data that confirms the validity of the model. © 2003 Elsevier... 

In this paper an integrated model has been developed that is capable of considering the effects of process parameters on the thermo-mechanical behaviour of the work-roll and the strip during hot rolling operations. The commercially finite element package ABAQUS is utilized to solve the governing equations, while an elasto-viscoplastic material behaviour is utilized in the model. The model may be employed in single-pass as well as multi-pass rolling layouts. Various aspects of the hot rolling process are predicted including temperature field and thermo-mechanical stresses within the work-roll as well as temperature, strain, and residual stresses distributions within the strip. To assess the... 

In this study, strain ageing during and after warm rolling of a carbon steel has been investigated. At the first step, the occurrence of serrated flow was studied by means of tensile tests at different temperatures and strain rates. In the next stage, warm rolling experiments were performed under different rolling conditions and then the samples were aged at the room temperature for a period of 3 months. For both aged and non-aged samples, tensile tests were employed to evaluate their mechanical properties. The results show that static strain ageing is possible to happen in the utilized ageing period and increases the yield stress of the aged steel. However, the samples that experience both... 

The mechanisms of cold roll welding of aluminium alloy to steel strip has been assessed based on a study of interfacial behaviour at deformations of up to 60% together with the surface characteristics of peeled Al clad steel strip. The proposed mechanisms are applicable where the contact surfaces are degreased and then scratch brushed before the rolling deformation. According to this mechanisms the scratch-brushed layers are fractured shortly after entering the roll gap at a reduction of approximately 10%, which is about the threshold deformation for the roll bonding of aluminium to steel. The transfer cracks formed then become wider so that the distance between each coherent block increases... 

This study investigates the roll decay of a fishing vessel by experiments and computational fluid dynamics (CFD) simulations. A fishing vessel roll decay is tested experimentally for different initial roll angles. The roll decay is also simulated numerically by CFD simulations and is validated against the experimental results. It shows that the roll damping could be obtained by CFD with high level of accuracy. The linear and nonlinear damping terms are extracted from the CFD roll decay results and are used in a potential-based solver. In this way we are using a hybrid solver that benefits the accuracy of the CFD results in terms of roll damping estimation and the fast computations of the... 

The control of texture and microstructure can be achieved by an appropriate thermomechanical treatment in industrial production. The effects of finish rolling temperature, cold reduction and annealing temperature on texture development and microstructure in Brass sheet were investigated. The role of deformation inhomogeneities on texture evolution has been considered. The formation of transition bands during hot rolling enforced the intensity of cube components. Shear bands increased the intensities of S and Cu components after cold rolling and at higher cold reductions. Transition from Cu to Y and Y to Bs was completed better because of mechanical twinning. Thermal twins annihilated the... 

An artificial neural network model, using a back-propagation learning algorithm is utilized, to predict the yield stress, elongation, ultimate tension stress, over(R, -) and {divides}ΔR{divides} during hot rolling, cold rolling and annealing of AA3004 aluminum alloy. Input nodes were chosen as the ratio of initial to final thicknesses, reduction, preheating time and temperature, finish rolling temperature and the final annealing temperature. The maximum error for predicted values was 6.35%, the average of absolute relative error was 0.57% and the RMS was 0.00998. It was found that the mechanical properties and anisotropy of AA3004 alloy sheets can be predicted by this approach. © 2006... 

Perovskite solar cells (PSCs) have shown rapid progress in a decade of extensive research and development, aiming now towards commercialization. However, the development of more facile, reliable, and reproducible manufacturing techniques will be essential for industrial production. Many lamination methods have been initially designed for organic photovoltaics (OPVs), which are conceptually similar to PSCs. Lamination could provide a low-cost and adaptable technique for the roll-to-roll production of solar cells. This review presents an overview of lamination methods for the fabrication of PSCs and OPVs. The lamination of different electrodes consisting of various materials such as metal back...