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FINISHING PROCESSES
Figure 2 Wettemper
equipment
Attribute
Type of mill
Capacity
Strip thickness
Strip width
Coil weight
Coil diameter
Main-drive power
Mill speed
Rolling force
Work roll diameter/
barrel length
Backup roll diameter/
barrel length
Elongation
Data
4-high
900 kt/a
0.33 mm
6001,620 mm
Max. 30 t
11002,000 mm
2 x 400 kW
Max. 900 m/min
14 MN
602587 mm/1,700 mm
15201,405 mm/1,700 mm
Max. 3%
Operational results
Excellent product quality:
Nitrite-free surface
50 per cent less spot rust
No brown streaks
No stains from liquid drops.
Service life of rolls:
No change compared to the wet process
Backup rolls 40,000 t
Work rolls 800 t.
Lifetime of brushes:
For work rolls 160,000 t
For backup rolls 160,000 t
(cleaning during back up roll change).
Technological effects:
Increase of rolling force (1015 per cent)
Temperature increase of roll surface (change in
work-roll crown, higher bearing temperature).
Benefits
Suitable for highest quality demands (ie, exposed
automotive sheets)
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SmartCrown
SmartCrown is a new type of roll contour that applies
lateral shifting of the work rolls to adjust the unloaded
and loaded roll-gap contourm to adjust the working
range of roll bending, and to match the relative crown
of the incoming strip. The SmartCrown contour
(Figure 5) can be described as a sum of a sinusoidal
and a linear function. Coefficients of this function are
chosen such that at an arbitrary roll-shifting position,
the resulting unloaded roll-gap profile is always
cosine-shaped. Therefore, continuous shifting allows
for continuous adjustment of the roll-gap profile.
The contour of the roll gap can be expressed by a
cosine function. The unloaded roll gap contour
corresponds to a certain portion of a cosine curve
around its vertex. The position of the barrel edge
corresponds to a certain angle, the contour angle.
By fine-tuning this angle, the transverse profile of the
resultant roll gap can be adjusted in such a way that
quarter buckles can be avoided (Figure 6). This is a
result of the fact that the local thickness reduction in
the quarter-buckle-sensitive area is decreased, since
the unloaded roll gap height is somewhat larger in
this region. A smaller local reduction results in a
reduced tendency towards longitudinal compressive
stresses in the strip, which are responsible for the
occurrence of strip buckling. The benefits of
SmartCrown are shown in Figure 7.
Modelling approaches for skin pass and
temper rolling
Respective improvements in the technological controls
for elongation and flatness counteract inconsistencies
born of a variety of process disturbances, resulting
mainly from the incoming material, in addition to other
factors such as acceleration/deceleration and slippage.
However, even rapid and accurate controls are not able
to immediately compensate for errors from setup
deviations. The more frequently changes in sheet sizes
are made, the more important this becomes.
Even today, almost all skin-pass and temper-mill
setups are created using offline calculations and trialand-error procedures during operation. Sophisticated
FINISHING PROCESSES
16(l-v )FW
R
= l+
Ebh
R
where R is the radius of the deformed work roll, R is
the nominal work roll radius, FW is the roll force, E the
Youngs modulus of the rolls, b the width and h the
reduction, can be used only when the roll deformation
is small. In the following 20 years numerous works
have been devoted to include an influence function
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b(x)= b0 -
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Thin-gauge models
In 1987, Fleck and Johnson published a theory for
cold rolling of thin foils that was an entirely new
approach to this subject. They were able to present a
theory that basically omitted the use of simplifying
presumptions on roll-flattening geometry, which for
older models can be considered as the main reason
for failure when applied to thin-gauge rolling.
In addition to the elastic and plastic zones upon
entry and exit to the roll bite, a key element was to
also introduce an intermediate zone called contained
plastic flow zone (Figure 9).
This approach takes into account the fact that the
work rolls can suffer extreme flattening in an
intermediate part of the contact region which, as an
upper limit, includes an infinite deformed roll radius,
yielding a flat roll surface parallel to the strip middle
plane. Since the flattened roll geometry is now
prescribed, the usual iteration to find a deformed roll
shape associated with a certain contact pressure
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