Abstract: Optimisation of the physical and mechanical properties of cold rolled thin strips is achieved by controlling the rolling parameters. In this paper, the factors affecting the asymmetrical cold rolling of thin low carbon steel strip have been studied at a speed ratio of 1.1 without lubricant applied. The effect of rolling parameters on the resulting microstructure was also investigated. It was found that under dry condition, work roll shifting and work roll cross angle can improve the strip profile, and the result is more significant with an increase of work roll cross angle rather than that of work roll shifting. However, there was no obvious change in microstructure. In addition, effects of rolling parameters on strip profile and microstructure have also been discussed.
Abstract: In this study, the influence of rolling process parameters such as the work roll cross angle and work roll shifting value on the strip shape and profile of aluminum have been investigated under dry conditions at a speed ratio of 1.3 using Hille 100 experimental mill. The strip profile was found to improve significantly with increase in work roll cross angle from 0o to 1o, with an associated decrease in rolling force. The effect of roll shifting (from 0 to 8mm) was not as significant as the roll cross angle. However, an increase in work roll shifting value achieved a similar decrease in rolling force as that of work roll cross angle. The effect of work roll shifting was also found to be maximum at an optimum roll speed of 0.0986 m/s for the desired thickness. Of all these parameters, the most significant effect of the strip shape profile was observed with variation of work roll cross angle. However, the rolling force can be a significantly reduced by either increasing the the work roll cross angle or work roll shifting.
Abstract: In the present study, response surface methodology has been used to optimize turn-assisted deep cold rolling process of AISI 4140 steel. A regression model is developed to predict surface hardness and surface roughness using response surface methodology and central composite design. In the development of predictive model, deep cold rolling force, ball diameter, initial roughness of the workpiece, and number of tool passes are considered as model variables. The rolling force and the ball diameter are the significant factors on the surface hardness and ball diameter and numbers of tool passes are found to be significant for surface roughness. The predicted surface hardness and surface roughness values and the subsequent verification experiments under the optimal operating conditions confirmed the validity of the predicted model. The absolute average error between the experimental and predicted values at the optimal combination of parameter settings for surface hardness and surface roughness is calculated as 0.16% and 1.58% respectively. Using the optimal processing parameters, the surface hardness is improved from 225 to 306 HV, which resulted in an increase in the near surface hardness by about 36% and the surface roughness is improved from 4.84µm to 0.252 µm, which resulted in decrease in the surface roughness by about 95%. The depth of compression is found to be more than 300µm from the microstructure analysis and this is in correlation with the results obtained from the microhardness measurements. Taylor hobson talysurf tester, micro vickers hardness tester, optical microscopy and X-ray diffractometer are used to characterize the modified surface layer.
Abstract: Vancron 40, a nitrided powder metallurgical tool
Steel, is used in cold work applications where the predominant failure
mechanisms are adhesive wear or galling. Typical applications of
Vancron 40 are among others fine blanking, cold extrusion, deep
drawing and cold work rolls for cluster mills. Vancron 40 positive
results for cold work rolls for cluster mills and as a tool for some
severe metal forming process makes it competitive compared to other
type of work rolls that require higher precision, among others in cold
rolling of thin stainless steel, which required high surface finish
quality. In this project, three roll materials for cold rolling of stainless
steel strip was examined, Vancron 40, Narva 12B (a high-carbon,
high-chromium tool steel alloyed with tungsten) and Supra 3 (a
Chromium-molybdenum tungsten-vanadium alloyed high speed
steel). The purpose of this project was to study the depth profiles of
the ironed stainless steel strips, emergence of galling and to study the
lubrication performance used by steel industries. Laboratory
experiments were conducted to examine scratch of the strip, galling
and surface roughness of the roll materials under severe tribological
conditions. The critical sliding length for onset of galling was
estimated for stainless steel with four different lubricants. Laboratory
experiments result of performance evaluation of resistance capability
of rolls toward adhesive wear under severe conditions for low and
high reductions. Vancron 40 in combination with cold rolling
lubricant gave good surface quality, prevents galling of
metal surfaces and good bearing capacity.
Abstract: High strength Fe-36Ni-base Invar alloys containing Al contents up to 0.3 weight percent were cast into ingots and thermodynamic equilibrium during solidification has been investigated in this study. From the thermodynamic simulation using Thermo-Calc®, it has been revealed that equilibrium phases which can be formed are two kinds of MC-type precipitates, MoC, and M2C carbides. The mu phase was also expected to form by addition of aluminum. Microstructure observation revealed the coarse precipitates in the as-cast ingots, which was non-equilibrium phase and could be resolved by the successive heat treatment. With increasing Al contents up to 0.3 wt.%, tensile strength of Invar alloy increased as 1400MPa after cold rolling and thermal expansion coefficient increased significantly. Cold rolling appeared to dramatically decrease thermal expansion coefficient.
Abstract: This study investigated the combined effect of cold rolling and heat treatment on the mechanical properties of Al-Ti alloy. Samples of the alloy are cast in metal mould to obtain 0.94-2.19wt% mixes of titanium. These samples are grouped into untreated (as-cast) and those that are cold rolled to fifty percent reduction, homogenized at 5000C and soaked for one hour. The cold rolled and heat treated samples are normalized (RTn) and quench-tempered (RTq-t) at 1000C. All these samples are subjected to tensile, micro-hardness and microstructural evaluation. Results show remarkable improvement in the mechanical properties of the cold rolled and heat treated samples compared to the as-cast. In particular, the RTq-t samples containing titanium in the range of 1.7-2.2% demonstrates improve tensile strength by 24.7%, yield strength, 28%, elastic modulus, 38.3% and micro-hardness, 20.5%. The Al3Ti phase being the most stable precipitate in the α-Al matrix appears to have been responsible for the significant improvement in the alloy’s mechanical properties. It is concluded that quench and temper heat treatment is an effective method of improving the strength-strain ratio of cold rolled Al-.0.9-2.2%Ti alloy.
Abstract: Spheroidization heat treatment was conducted on the SK85 high carbon steel sheets with various initial microstructures obtained after cold rolling by various reduction ratios at a couple of annealing temperatures. On the high carbon steel sheet with fine pearlite microstructure, obtained by soaking at 800oC for 2hr in a box furnace and then annealing at 570oC for 5min in a salt bath furnace followed by water quenching, cold rolling was conducted by reduction ratios of 20, 30, and 40%. Heat treatment for spheroidization was carried out at 600 and 720oC for the various time intervals from 0.1 to 32 hrs. Area fraction of spheroidized cementite was measured with an image analyzer as a function of cold reduction ratios and duration times. Tensile tests were carried out at room temperature on the spheoidized high carbon steel.
Abstract: In this study we propose a novel monitor hydraulic
automatic gauge control (HAGC) system based on fuzzy feedforward
controller. This is used in the development of cold rolling
mill automation system to improve the quality of cold strip. According to features/ properties of entry steel strip like its average
yield stress, width of strip, and desired exit thickness, this controller realizes the compensation for the exit thickness error. The traditional methods of adjusting the roller position, can-t tolerate the variance in
the entry steel strip. The proposed method uses a mathematical model
of the system together with the expert knowledge to perform this adjustment while minimizing the effect of the stated problem. In
order to improve the speed of the controller in rejecting disturbances
introduced by entry strip thickness variations, expert knowledge is added as a feed-forward term to the HAGC system. Simulation
results for the application of the proposed controller to a real cold mill show that the exit strip quality is highly improved.
Abstract: Deep cold rolling (DCR) is a cold working process, which easily produces a smooth and work-hardened surface by plastic deformation of surface irregularities. In the present study, the influence of main deep cold rolling process parameters on the surface roughness and the hardness of AISI 4140 steel were studied by using fractional factorial design of experiments. The assessment of the surface integrity aspects on work material was done, in terms of identifying the predominant factor amongst the selected parameters, their order of significance and setting the levels of the factors for minimizing surface roughness and/or maximizing surface hardness. It was found that the ball diameter, rolling force, initial surface roughness and number of tool passes are the most pronounced parameters, which have great effects on the work piece-s surface during the deep cold rolling process. A simple, inexpensive and newly developed DCR tool, with interchangeable collet for using different ball diameters, was used throughout the experimental work presented in this paper.
Abstract: Deep cold rolling (DCR) and low plasticity burnishing (LPB) process are cold working processes, which easily produce a smooth and work-hardened surface by plastic deformation of surface irregularities. The present study focuses on the surface roughness and surface hardness aspects of AISI 4140 work material, using fractional factorial design of experiments. The assessment of the surface integrity aspects on work material was done, in order to identify the predominant factors amongst the selected parameters. They were then categorized in order of significance followed by setting the levels of the factors for minimizing surface roughness and/or maximizing surface hardness. In the present work, the influence of main process parameters (force, feed rate, number of tool passes/overruns, initial roughness of the work piece, ball material, ball diameter and lubricant used) on the surface roughness and the hardness of AISI 4140 steel were studied for both LPB and DCR process and the results are compared. It was observed that by using LPB process surface hardness has been improved by 167% and in DCR process surface hardness has been improved by 442%. It was also found that the force, ball diameter, number of tool passes and initial roughness of the workpiece are the most pronounced parameters, which has a significant effect on the work piece-s surface during deep cold rolling and low plasticity burnishing process.
Abstract: Modern manufacturing facilities are large scale,
highly complex, and operate with large number of variables under
closed loop control. Early and accurate fault detection and diagnosis
for these plants can minimise down time, increase the safety of plant
operations, and reduce manufacturing costs. Fault detection and
isolation is more complex particularly in the case of the faulty analog
control systems. Analog control systems are not equipped with
monitoring function where the process parameters are continually
visualised. In this situation, It is very difficult to find the relationship
between the fault importance and its consequences on the product
failure. We consider in this paper an approach to fault detection and
analysis of its effect on the production quality using an adaptive
centring and scaling in the pickling process in cold rolling. The fault
appeared on one of the power unit driving a rotary machine, this
machine can not track a reference speed given by another machine.
The length of metal loop is then in continuous oscillation, this affects
the product quality. Using a computerised data acquisition system,
the main machine parameters have been monitored. The fault has
been detected and isolated on basis of analysis of monitored data.
Normal and faulty situation have been obtained by an artificial neural
network (ANN) model which is implemented to simulate the normal
and faulty status of rotary machine. Correlation between the product
quality defined by an index and the residual is used to quality
classification.