ROBUST DESIGN OF ROLL PASS FOR REDUCED GEOMETRIC VARIANCE IN HOT ROLLING OF STEEL ROD A Thesis. Presented in Partial Fulfillment of the Requirements for the Degree Master of Science in the Graduate School of The Ohio State University by Koji Yoshimura, B.E. ‘The Ohio State University 1995 Master’s Examination Committee: Approved by Rajiv Shivpuri ‘ Jerald Brevick Z 4 Advisor industrial and Systems Engineering Graduate ProgramTo my wife Kazuko and our little daughier YukiACKNOWLEDGMENT I would like to express my sincere appreciation to my advisor Prof. Rajiv Shivpuri for his continuous guidance and support. His knowledge and achievements in both theoretical and practical fields of metal forming process motivated me to seek more advanced study in my work. My deep appreciation to him dates back to more than two years ago; his strong back up supported me to join the ISE department of the Ohio State University as a master-course student. I am also grateful to Prof. Taylan Altan (Director, ERCI/NSM) for his guidance. I would like to thank to Dr. Wooyong Shin (former graduate associate at the Ohio State University) and Prof. Jun Yanagimoto (the University of Tokyo) for their technical support in the field of rolling analysis and continuous encouragement. Also great thanks to ERC members. Lam utterly grateful to Prof. Kosuke Ishii (Stanford University) for his enthusiastic guidance in the field of design optimization, His advanced vision in the mechanical design made it possible to perform the complex experiments and analysis. I am also thankful to Dr. Jyh-Cheng Yu (former graduate associate at the Ohio State University) for his support in the design field. The provision of the two year period and the financial support for my graduate study by Nippon Steel Corporation is gratefully acknowledged. The technical information provided by Mr. Hiroshi Ikeda and Mr. Yasuhito Sasaki (Kimitsu Works, Nippon Steel Corporation) was also indispensable for this research,To my wife Kazuko and our daughter Yuki, thank you for your encouragement. I know it was not always easy for you to live in the U.S.A. May, 1995 ‘The Ohio State University Columbus, Ohio U.S.A. ivVITA July 1, 1961 .. Bom in Fukuoka, Japan . B.E., Marine Engineering, The University of Tokyo, Tokyo, Japan March, 1984 1984 - 1993 . Production Engineer, Nippon Steel Corporation, Kimitsu, Chiba, Japan PUBLICATIONS Yoshimura, K., Shivpuri, R. and Ishii, K. (1995) "Robust Design of Square-to-Box Rolling of Steel Rods." Submitted to the 1995 ASME Design Automation Conference. FIELDS OF STUDY Major Field: Industrial and Systems Engineering Studies in: Metal Forming, Process Design and Modeling, Quality Control and Management in ISE Department Life-cycle Engineering and Optimization in ME Department Linear Regression Analysis in STAT DepartmentTABLE OF CONT! PAGE ACKNOWLEDGMENTS VITA ..... TABLE OF CONTENTS ... vi LIST OF TABLES xi LIST OF FIGURES CHAPTERS PAGE I INTRODUCTION 1.1 Background. . 1.2 Introduction to Rod Rolling P: 1.3 Problem Definition 1.3.1 Outline of In-line Quality Control . 1.3.2 Problem in Rolling Process Control ... 1.3.3. Need for Robustness in Lateral Spread 1.4. Research Targets and Objectives ass. 1.5 Research Approach .. 1.6 Report Outline ... eIIwAnk ewe ER Tl REVIEW OF ROLLING PROCESS AND TECHNOLOGY ... . 2.1 Outline of Rod Rolling Process Peoeerenteneeee aS) © vim 2.1.1 Overview of Integrated Process 2.1.2 Wire Rod Process 2.2 Basic Theory of Rolling .. 2.3. Previous Work in Rolling Analysis 14 METHODOLOGY OF RESEARCH ..... 16 3.1 Outline of Taguchi Method 16 3.1.1 Design Concept 16 3.1.2. Configuration Development 3.1.3. Parameter and Tolerance Design 3.1.4. Previous Work in Robust Design 3.2. Outline of FEM Code TASKS ... 3.2.1. Background of TASKS 3.2.2 Development of TASKS 3.2.3. Application and Results . 18 20 3.3. Concept of Parameter Setting 3.3.1 Factors Affecting Lateral Spread ... 3.3.2 Geometric Factors Frictional Factors Material Factors 23 Basic Concepts of Parameter Setting SCREENING OF PARAMETERS .. 4.1 Basic Methodology of the Screening Experiments... 4.2. Frictional Factor on Spread: Oval-Square Pass .. 4.2.1. Regression Analysis .... 31 32 4.2.2. Diagnostics of the Regression 4.2.3 Discussion 4.2.4 Conclusions 4.3. Frictional Factor on Spread: Square-Oval Pass 4.3.1. Regression Analysis ..... 4.3.2. Diagnostics of the Regression... 43.3. Discussion vii4.3.4 Conclusions 4.4 Frictional Factors on Torque .. 4.4.1 Regression Analysis 44.2 Discussion 4.4.3 Conclusions 4.5 Material Factors on Spread and Torque 4.5.1 Flow Stress of the Hot Steel. 4.5.2 Material Factors on Spread: Oval-Square Pass. 4.5.3 Material Factors on Spread: Square-Oval Pass. 4.5.4 Material Factors on Torque: Oval-Square Pass. 4.5.5 Material Factors on Torque: Square-Oval Pass 4.6 Summary of the Screening Experiments APPROACH TO ROBUST DESIGN OF A SQUARE-TO-BOX PASS 5.1 Parameters for Robust Design . 5.1.1 Controllable Design Parameters 5.1.2. Uncontrollable Design Parameters. 53 5.1.3 Uncontrollable Process Parameters. 5.1.4 Quality (Output) Parameters 5.2. Design of Experiments 5.2.1 Inner Array (Design Parameters) ..... 5.2.2 Outer Array (Noise Parameters) 5.2.3. Simulation Experiments 5.3 Results of the Experiments .. 5.3.1 Analysis of Variance 5.3.2. Regression Analysis 5.3.3 Robust Design for Consistent Lateral Spread 5.4 Comparison with Empirical Knowledge and Common Sense . 68 5.4.1 Interpretation of Robustness Trends 69 5.4.2 Examination of Parameter wi/hi 69 5.4.3 Examination of Parameters 2R/hi and ha/hi 70 5.5 Robust Design Guidelines 5.5.1 Parameter wi/hi .. viii5.5.2 Parameter 2R/h 5.5.3. Parameter ha/hi .. 5.5.4 Parameter a 5.5.5 Parameter wo/ws 5.5.6 Parameter 2r/v1 5.5.7 Example of the Design Procedure 5.6 Summary of Square-to-Box Roll Pass Design APPROACH 70 ROBUST DESIGN OF A SQUARE-TO-OVAL PASS 6.1 Parameters for Robust Design ... 6.1.1 Controllable Design Parameters 6.1.2 Uncontrollable Design Parameters 6.1.3 Uncontrollable Process Parameters. 6.1.4 Process Noise — Twist Angle 6.1.4 Quality (Output) Parameters 6.2. Design of Experiments 6.2.1 Inner Array (Design Parameters) 6.2.2 Outer Array (Noise Parameters) ... 6.3. Results of the Experiments 6.3.1 Analysis of Variance 6.3.2 Regression Analysis 6.3.3 Robust Design for Consistent Lateral al Spread - 6.4 Comparison with Empirical Knowledge and Common Sense . 6.4.1 Interpretation of Robustness Trends... 6.4.2 Examination of Parameter wi/hi 6.4.3. Examination of Parameters 2R/hi and ha/hi 6.4.4 Examination of Parameter 2r/w1 6.5 Robust Design Guidelines 6.5.1 Parameter wi/hi ... 6.5.2. Parameter 2R/hi 6.5.3 Parameter h2/hi 6.5.4 Parameter 2rAvi ... 6.5.5 Example of the Design Procedure...6.6 VII EVALUATION OF THE NEW DESIGN Summary of Square-to-Oval Roll Pass Design 100 7.1 Parameters for Evaluation 100 7.1.1 Design Parameters .. 100 7.1.2 Noise Parameters... 101 7.2 Results of the Evaluation 103 7.3. Discussion 106 7.3.1 Variance in Stock Width . 106 7.3.2. Profiles of the Rolled Stock 107 7.4 Conclusions ... 108 VIIL_ A BRIEF INTRODUCTION TO ROBROLL ... 109 8.1 8.2 8.3 109 116 110 Objective of Development Design Feature of the System . Basic Function of the System . 8.3.1. Main Job Flow . 110 8.3.2 Benchmark Tasks M1 8.3.3 Structure 112 IX SUMMARY AND FUTURE DIRECTION .. 114 9.1 Summary 14 9.2 Conclusions 116 9.3. Application 116 9.4 Future Direction . 117 REFERENCES... 118 APPENDICES Appendix-A Data Tables of Screening Experiments 123 Appendix-B Data Tables of Evaluation Experiments. 126Table 4. Table 4.3: Table 4.4: Table 5 Table 5.5: Table 5.6: LIST OF TABLES PAGE Inner/Outer OA Parameter Design Experiment (Ross, 1988) - 19 Result of the Regression Analysis in Correlation of Spread (Oval-Square Pass) Result of the Regression Analysis in Correlation of Spread (Square-Oval Pass) ... 39 Result of the Regression Analysis in Correlation of Torque (Square-Oval Pass) .. Material Conditions for the Screening of the Material Factors Parameters Defined for Experiments in the Square-Box Pass Levels of Controllable Factors (Square-Box) L18 Orthogonal Array for Controllable Factors (Square- Box) Levels of Uncontrollable Factors (Square-Box) L4 Orthogonal Array for Uncontrollable Factors (Square- Box) Results of the Experiments Using TASKS over L18 OA (Square-Box)Table 5.7: Table 5.8: Table 5.9: Table 6.1: Table 6.2: Table 6.3: Table 6.4: Table 6.5: Table 6.6: Table 6.7: Table 6.8: Table 6.9: Table 7.1: Table 7.2: Table 7.3: Table 8.1: Table 9.1: Table A.1 Table A.2: ANOVA Summary on Percentage Spread (Square-Box) Regression Analysis (Square-Box) Preferable Parameters and Example of Design (Square-Box) Parameters Defined for Experiments in the Square-Oval Pass Levels of Controllable Factors (Square-Oval) L9 Orthogonal Array for Controllable Factors (Square-Oval) Levels of Uncontrollable Factors (Square-Oval) . 85 L8 Orthogonal Array for Uncontrollable Factors (Square- Oval) 86 Results of the Experiments Using TASKS over L9 OA. (Square-Oval) ANOVA Summary on Percentage Spread (Square-Oval) Regression Anal (Square-Box) Preferable Parameters and Example of Design (Square- Oval) Design Parameters of Box and Oval Passes in Original and New Design 101 Levels of Uncontrollable Factors (Evaluation Experiments) . 101 Orthogonal Arrays for Uncontrollable Factors (Evaluation) . 102 Benchmark Tasks of the System 112 Parameters in the New Design of the Square-Box-Oval Sequence 116 Background Data (Oval-Square Experiments) 124 Background Data (Square-Oval Experiments) 124Table A.3: Table A.4: Table B.1: Table B.2: Simulation Data Compared with Actual Measurements (Oval- Square Experiments) Simulation Data Compared with Actual Measurements (Square-Oval Experiments) Simulation Data in Box-Pass Evaluation Simulation Data in Oval-Pass Evaluation xiii 125 125 127 127FIGURES Figure 1.1: Figure 1.2: Figure 1.3: Figure 2.1: Figure 2.2: Figure 2.3; Figure 2.4: Figure 2.5: Figure 3.1: Figure 3.2: Figure 3.3: Figure 3.4: LIST OF FIGURES ‘T-pass Sequence for a Roughing Train of a Wire Rod Mill Feedback Cycle for In-line Quality Control Mechanisms of Flaw Formation Production Process of an Integrated Steel Plant (Kimitsu ‘Works, Nippon Steel Corporation) ul Layout of a 4-strand Wire Rod Mill (Kimitsu Works, Nippon Steel Corporation) Bird's-eye View of the Wire Rod Mill (Kimitsu Works, Nippon Steel Corporation) Inside View of an NT Block Mill (Roberts, 1983) Basic Principles of a Rolling Process Classes of Control Factors (Ross, 1988) Application of FSEM to the Shape Rolling Process (Kim er al,, 1991) Concept of Spread by Side-fold and Bulge (Sheppard et al., 1981) Equivalent Rectangle Transformation Method (Shinokura er al., 1982) xivFigure 3.5 Figure 4.1 Figure 4.2: Figure 4.3: Figure 4.4: Figure 4.5 Figure 4.6: Figure 4.7: Figure 4.8: Figure 4.9: Figure 4.10: Figure 4,11: Figure 4.12: Figure 4.13: Figure 4.14: Figure 4.15: Figure 5.1: Figure 5.2: Figure 5.3: Figure 5.4: Figure 5.5: Concept of General and Particular Parameters Wood-Printing Method to Obtain the Rolling Profiles Oval-Square and Square-Oval Pass for the Experiments .. Correlation of ws/va and m (Oval-Square Pass) Plots for Diagnostics of the Correlation (Oval-to-Square) Roll Wear and Lateral Spread Correlation of ws/va and m (Square-Oval Pass) Plots for Diagnostics of the Correlation (Square-to-Oval) Ts/Ta on tonnage and m (Oval-Square Pass) Ts/Ta on tonnage and m (Square-Oval Pass) Flow Stress and Temperature (Plain Carbon Steel) (Data from Altan ef al., 1983, formula from Misaka et al., 1967) Distribution of ws/wa (Oval-Square Pass) D bution of ws/va (Square-Oval Pass) Distribution of T's/Ta (Oval-Square Pass) Distribution of Ts/Ta (Square-Oval Pass) Effect of the Frictional and Material Parameters... Geometry of a Box Pass Outline of the Roll Re-grinding Virtual Data Series of ws/wa That Is Identical to the Series m=0.5 Estimation of the Depth of Wear for the Maximum Tonnage Groove Height of a Box Pass and the Roll Separating Force (Primary data from Nippon Steel Corp.) xvFigure 5.6: Figure 5.7: Figure 5.8: Figure 5.9: Figure 5.10: Figure 5.11: Figure 5.12: Figure 5.13: Figure 5.1 Figure 5.15: Figure 5.16: Figure 5.17; Figure 6.1: Figure 6.2: Figure 6.3: Figure 6.4: Figure 6.5: Figure 6.6: Figure 6.7: Mechanism of the Strand Factor (Case of 4-strand) Process Noise Factors and Effects on hz (Square-Box Pass) Parameter Definition of the Deformation Mean of S/N in Each Level and Parameter (Square-Box) Mean Performance of Sp in Each Level and Parameter (Square-Box) Correlation of S/N to Edge Filling Ratio Results of Non-uniform Deformation (Mielnik, 1991) .. Correlation of Double-bulge Ratio to A-value (Square-Oval) Forces Acting on Material during the Deformation Quality of the Free Edge Surface Strain Distribution on Material Rolled by a Box Groove .... Acceptable Range of the Roll Diameter and Reduction (Square-Box) Geometry of an Oval Pass Groove Height of an Oval Pass and the Roll Separating Force (Primary Data from Nippon Stee! Corp.) Process Noise Factors and Effects on h2 (Square-Oval Pass) Roll-bite in a Square-Oval Pass 83 Mean of S/N in Each Level and Parameter (Square-Oval) Mean Performance of S, in Each Level and Parameter 89 (Square-Ovai) Correlation of S/N to Groove Filling Ratio xviFigure 6.8: Figure 6.9: Figure 6.10: Figure 7.1: Figure 7.2: Figure 7.3: Figure 7.4: Figure 7.5 Figure 7.6: Figure 8.1: Correlation of Double-bulge Ratio to A-value (Square-Oval) 92 Strain Distribution on Material Rolled by an Oval Groove Acceptable Range of the Roil Diameter and Reduction (Square-Oval) The Square-Box-Oval Sequence Maximum and Minimum of Stock Width in Billet and Each Pass 102 Standard Deviation in Stock Width after Each Pass . 103 Distribution of the Filling Ratios 103 Profile of the Stock in Original Design Pass 104 Profile of the Stock in New Design Pass 105 Structure of the Main Stream in ROBROLL, 113, XviCHAPTER I INTRODUCTION 1.1 Background Rolling is an efficient method for mass production of steel products, and the efficiency is getting higher by the development of rolling machinery. On the other hand, since about a decade ago, the social trend of diversification has grown to require higher and more various qualities and service. It is now a common sense that the most important issues for the social responsibilities of the steel industries include customer satisfaction in quality and service as well as supply of required amount. The quality issues in shape or rod rolling process include the dimensional accuracy, surface quality, and prevention of inner defects in the finished part. We must seek a roll pass sequence that produced quality parts under manufacturing conditions that may involve significant variation or noise. However, in the real world of shape rolling, roll pass design is more of an “art” that depends on experimental knowledge of experts than a technology. To be independent of expertise that requires years of experience, and to further seek improvements in the quality of rolled parts, the steel industries need a systematic and quantitative methodology for robust design of the rolling process.2 The service issue may be a new concept in manufacturing. The principle of mass production advocated by Adam Smith wo hundred years ago can not last any more; suppliers can not get the customer satisfaction by simply manufacturing the standardized products. Instead, customers or consumers have become to require personalized products which best fit their own demands. In respect of this social trend, the new technologies such as the AS/RS and the computer-controlled storage yard have been developed for Just In Time (IIT) concepts in storage and delivery. In rolling process, the technologies being developed such as size-free and schedule-free rolling, as well as the development of new material, will play important roles in the near future of rod rolling. For the "construction" of those new technologies which require quite sensitive and delicate process control, the basic "foundation" of robust rolling process should be established. These trends as social background pose an important key issue “variation,” which gives us the motivation to develop the analytical methodology for the robust design of roll pass, especially in the field of shape rolling whose 3-D deformation is much more complex than sheet rolling. #2 Oval) #3 (Slug) c™é 1 c™« c™é 1 cu“ eee 2S oe —- ST —— AT #4 (Oval) #5 (Sduare) #6 (Oval) #7 (Round) Figure 1.1: 7-pass Sequence for a Roughing Train of a Wire Rod Mi1.2 Introduction to Rod Rolling Pass Figure 1.1 shows a typical seven-pass sequence for the rough-rolling train of a rod rolling mill, This sequence produces round-shaped products from square-shaped billets. ‘The characteristics and roles of each pass are following. #1 box pass reduces the height of the billet to provide appropriate thickness for the following #2 oval pass. This pass may be called an oval former, which is usually used as the very first pass of the sequence. Usually high in reduction of area, but hard to get ‘uniform deformation. #2 oval pass is usually thin and wide oval to take high reduction of area from the rectangular Billet (product of the box pass) and to make up for the non-uniformity in deformation of the previous pass. #3 slug pass is a kind of round pass, but larger in height than width, Thus this pass is sometimes called a slug-oval. Since the previous oval is thin and wide, a complete round or a square would make wrinkle-like flaws on the side surface of the rolled stock. #4 oval pass is usually thicker than #2 oval to provide appropriate oval shape for the succeeding square pass #5 square pass is necessary to create the square-oval sequence, which can take the highest reduction of area. #6 oval pass, associated with the previous square pass, can take high reduction of, area, However, too thin oval would possibly make wrinkle-like flaw on the side surface if the reduction. Control of this pass directly affects the quality of the following final pass, #7 round pass makes the final products of this roughing sequence. To provide material for the following intermediate or finishing sequence, this pass has to keep the geometric deviation as small as possible.4 The geometry of the product at the seventh pass has to be quite accurate, for instance, 42% in diameter, since the deviation often results in inappropriate profile in the following sequence (intermediate or finishing train), like over- or under-filling, which affects the quality of final products. 1.3 Problem Definition 1.3.1_Outline of In-line Quality Control In the rolling site of steel wire rod, the inspection process pla s an important role. The main job of an in-line inspection process includes: (1) Inspection of surface defect (2) Inspection of the coiling quality and outlook (3) Inspection of size tolerance (4) Inspection of inner defect ‘The inspectors apply those checking items for every product just rolled and coiled. If they find any problem, the corresponding coil will be down-graded, or, in an extreme case, scrapped. At the same time, they will inform the rolling and/or coiling process operators of the conditions of the defect. This action, feedback to production process, is a very important job item for the inspection process as well as grading the products. The corresponding process operators will check their own process and take action to remove the cause of the defects. They may even order the general operator (or the foreman) to stop the line to take their action. Some business researchers call this cycle of the in-line quality control "poka yoke" (a Japanese term that means preventing mistakes). Figure 1.2 represents the feedback cycle of the quality control.due to coiling proess ¥ check, }{ inspection -~ heck Reheating Rough Rolling [] Finish Rolling ction ‘Tue to rolling proc Figure 1.2: Feedback Cycle for In-line Quality Control 1.3.2_Problem in Rolling Process Control The most important action in the feedback cycle is to specify the cause of defects. That may be easy if the defect is irregular tolerance in diameter or disorder in coiling; they are visible. The hardest type of defect for the process operators to specify the causes is surface flaw, whose mechanism of formation is invisible. Then the rolling operators try to discriminate the causing pass and strand from the information provided by the inspection process. In this stage, the first action that the rolling operators take is to check the profile of rolled stock at each suspicious pass. There are two typical causes of surface flaw; overfilling and underfilling. ‘The following description explains the mechanisms of the surface flaw formation taking an oval-to-square rolling process as an example. (1) An overfilled oval pass makes "fins" on one or both sides of the rolled stock. When the following square pass rolls this stock, the grooves compress the "fins" that will be folded and create crevasse-like flaws. (2) An underfilled oval pass makes a short and thick oval. When the following square pass rolls this stock, the corners of the rectangle-like oval will also be folded because the edge of the oval does not fit the top of the square. Figures 1.3 (a) and (b) above show the mechanisms of flaw formation by overfilling and underfilling, respectively.~— Possible Flaws / Na ZA > > ANTS (a) (b) Figure 1.3: Mechanisms of Flaw Formation (a) caused by overfilling (b) caused by underfilling 3 Need for Robustness in Lateral Spread This variance in filling is related to the noise factors that exist in the rolling site, such as variance in material components, billet geometry, roll diameter, friction between rolls and material, roll wear, and so forth. Although the rolling operators aim to get appropriate profile in each pass, it is impossible for them to always watch the profiles in all of the passes. Furthermore, recent social trend of increasing product variation (e.g., odd size, special ingredients, etc.) tends to enhance the influence of uncontrollable factors larger. In the future technologies such as size-free, schedule-free, and newly developed material, one of the key issues is that the products with wide variation in their properties share the same process and/or equipment based on the principle of flexible manufacturing system. As the basis of those new technologies, the process must be least sensitive to the process noise factors. These problems pose the great need for roll passes designed to be less sensitive against the process noise factors. That is, roll pass design for robustness in lateral spread is in large demand not only for improvement in basic quality but also for social responsibility to supply what, when and how customers desire,1.4 Research Targets and Objectives This research focuses on the robust optimization of the rod rolling pass design in lateral spread. The typical rough-rolling patterns of square(rectangle)-to-box pass and square(rectangle)-to-oval pass are subject to be the targets of this research because an oval pass has its characteristic of large variance in spread because of its open geometry (close to flat). The variance in spread, which may result in overfill or underfill, often causes surface flaw in product geometry. Besides that, the variance of spread in an oval pass is often affected by that in the previous box pass, the "oval former”, as well. To achieve this purpose, the specific objectives of this research are following: (1) To prepare and examine suitable parameters to be the design factors and process noise factors, based on the previous studies on rolling and practical process data. (2) To design experiments and develop the robust design guidelines of a square-box pass, the oval former, and a square-oval pass. (3) To organize the robust design guidelines and approach to the development of an application software for robust design of roll passes. 1.5 Research Approach Development of numerical methods enabled rolling engineers to visually observe the complex phenomena during the rolling process. Some of those methods have already in practical use for process control and management. The next stage of those numerical methods is application to the design issues of roll pass. Some former studies have advanced to this field (Kennedy, et al., 1983, Shivpuri et al., 1992).8 On the other hand, many researchers have developed mechanical design concepts for robustness on the basis of the Taguchi method and its extensions, Their challenge in robust design techniques is dealing with several theories in design optimization, However, few studies in the past have addressed robust process design. Those techniques developed over the different fields of study lead to the new approach of process design optimization. Numerical analysis of rolling process will provide several information in rolling deformation, while robust design theories will analyze the numerical data for design optimization. This research investigates this issue by combining robust design technology with numerical simulation for the rolling process (Kim et al., 1991). 1.6 Report Outline Chapter If reviews the rolling process and related technology, including previous work in rolling analysis. Chapter III discusses the basic methodology of this research; design for robustness with Taguchi method, finite element computer code TASKS, and the idea of parameter setting for experiments. Chapter IV describes the screening experiments to examine the effects of frictional and material noise factors by employing statistical analysis of the simulation data compared with practical measurements. Chapter V and Chapter VI develop the robust design methodology and guidelines for the design of a square-to-box pass and squafe-to-oval pass, respectively. The research9 process in each chapter consists of over the experimental design, analysis of variance, parameter and tolerance design, and analysis of robustness trends. Chapter VII evaluates the robustness in an example of a square-box-oval sequence designed on the guidelines developed in this study, comparing with a sequence conventionally designed. Chapter VIII introduces the guidance system for robust design of a square-box and ‘square-oval roll pass developed on the basis of the results of Chapter V and V1. Finally, Chapter IX summarizes the results and achievements of this research and states the future directions.CHAPTER II REVIEW OF ROLLING PROCESS AND TECHNOLOGY 2.1 Outline of Rod Rolling Process Overview of Integrated Process Figure 2.1 shows an example of the throughout process for stee! products. The processes shown in bold letters are rolling processes, while underlined ones indicate final product processes. Since late 1970's continuous casting has been the main method for near-net shape manufacturing of blooms and slabs. Here, a break-down process from blooms to billets is usually necessary for production of wire rods and/or bars since the billets have too small cross section to be continuous-casted. Billet casting technologies for high grade steel are now under development. 2.1.2 Wire Rod Process Figure 2.2 illustrates an example of the layout of a wire rod rolling line (Kimitsu Works, Nippon Steel Corporation, Japan). This line has all horizontal multi-strand roughing / intermediate mills and no-twist finishing mills, among which some leopers are laid out. Figure 2.3 shows the birds-eye view photograph of the same line. 10ll Blast Furnace (Rare Metal) Basic Oxigen Fumace (Refined Steel) ee I Continuous Caster (Blooms) Continuous Caster (Slabs) oT Billets WideFrange Beams — Plates ~_ Hot Rolled Sheets | ‘Sheet Piles | | Wire Rods Pipes Cold Rolled Sheet Galvanized Sheets Figure 2.1: Production Process of an Integrated Steel Plant (Kimitsu Works, Nippon Stee] Corporation) Figure 2.2: Layout of a 4-strand Wire Rod Mill (Kimitsu Works, Nippon Steel Corporation)Figure 2.3: Bird's-eye View of the Wire Rod Mill (Kimitsu Works, Nippon Stee! Corporation) Figure 2.4: Inside View of an NT Block Mill (Roberts, 1983)13 All horizontal continuous mill was developed by C.H.Morgan in 1878. Instead of locating rolls in V-H arrays, he introduced twi 1g guides on the mill to twist the rolled stock between stands into the proper position for rolling. This mill made it possible to roll more than one rod at a time, this being impossible with V-H mills. No-twist (NT) block mill was first installed on a mill in 1966. ‘The unit utilizes small- diameter rolls, oriented 90° to each other and tilted on a 45°-axis, as seen in Figure 2.4, The small work rolls made of tungsten carbide rings, with a diameter of 6-8 inches, allow greater reductions of area to be taken with no appreciable increase in width of the cros section, The 8~10 pairs of rolls are driven by a common high-power motor with two long shafts to transfer the torque to upper rolls and lower rolls. The compact and rigid roll housings have high mill modules that keeps precise sizing, These characteristics of a NT block mill enable the rod manufacturing line to roll in very high speed, nowadays as fast as 100 m/sec. Figure 2.5: Basic Principles of a Rolling Process14 2.2 Basic Theory of Rolling To understand the mechanics of the rolling process, let us discuss a simple case of flat rolling in which the reduction of a rectangular stock is taking place (Figure 2.5). The stock enters the rolls at point 1 and leaves at point 2. Initially the material has width w, thickness h,, cross-sectional area A, and length L;,. After rolling, it has width w2, thickness /, cross-sectional area Az, and length L? Reduction in cross-sectional area is expressed as : Ar = [(A}-Az)/Aj] x 100 (%) (1) Since the same volume of material leaves the rolls as enters them, this reduction of area leads to elongation and spread. Elongation is expressed as the ratio of the final length to initial length or as percentage of the init I length as follows; + Elongation factor 1 E=Ly/Ly (2-2) * Percentage elongation = [(Lz- Ly)/L)] x 100 =(E-1)x100 (%) (2-3) Spread is due to lateral flow of material and is expressed in the following ways : + Absolute spread 2 Sa= wo wy (2-4) + Percentage spread: Sp = [(w- w,) /w,] x 100 (%) (2-5) * Proportional spread: S,= [(w2- w))/(Ay- h2)] x 100 (%) (2-6) 2.3 Previous Work in Rolling Analysis The shape rolling process includes complex 3-D deformation that attracted many researchers who focused primarily on empirical models. Helmi et al. (1968) conducted experiments covering a very wide range of geometric factor in flat rolling process and15 developed a reasonable formula for prediction of lateral spread ratio. El-Kalay et al. (1968) conducted experiments in flat rolling and clarified the effect of friction between rolls and material on lateral spread and roll separating force. In shape rolling, Shinokura et al. (1982) developed a formula for prediction of lateral spread in rod rolling process. Numerical analysis of rolling process has become leading method since 1980's. Kiuchi et al. (1987) developed a three-dimensional finite element method to simulate the shape rolling process. Kim et al. (1991) simplified Kiuchi's method by combination of two-dimensional finite element method and slab element method. Most of these methods predict physical state of rolling accurate enough for industries to practically use them as a tool for process control and management.CHAPTER III METHODOLOGY OF RESEARCH The characteristics of this research lie in its methodology; the combination of the Tagvchi's concept and FE simulation technique. This chapter explains the basis of Taguchi method and FE simulation code TASKS, followed by the concept of parameter design to make the most of these techniques. 3.1 Outline of Taguchi Method Taguchi's method rests upon two basic principles: (1) A limited set of experiments is performed to determine the sensitivity of the quality measures (observable factors that determine the quality of the products) to various controllable parameters and to uncontrollable parameters. (2) Design the product and process so that the sensitivity of the quality measures to noise is minimized. In other words, design the product/process so that the process can operate in a regime that minimize the effects of uncontrollable process variations. 1617 Taguchi categorizes the design process into three phases: + System design: concept generation, configuration development. + Parameter design: setting parameters of the configuration + Tolerance design: setting the tolerances on the nominal values of the parameters. In his view, off-line quality control happens at stage (2), in which the parameters should be set so that they are insensitive to variations. On-line control focuses on the production process to match the tolerance design and to reduce the variations. This study focuses on the off-line quality control. 3.1.2__Configuration Development A production process includes variations which come from various factors. (1) Control factors: Factors for which designers have control, e.g. parameter set points. (2) Noise factors: Factors for which designers do not have control. It may consist of following three categories: * Outer noise: environmental noise (temperature, operational conditions, ete.) + Inner noise: changes in the product itself (wear, shrinkage, material property change, etc.) + Product noise: part-to-part variations (manufacturing error, facility variation, etc.) Taguchi then defines the objective criteria as Loss functions in developing his design method with emphasis on robustness: Loss = k[V +(F-m)*] G-) where Vis variance of performance, m is mean performance, and ¥ is the output. This general form of function represents a nominal-is-best situation. The function consists of two parts: the variance and the relative location of the mean of performance. That suggests18 the product characteristics needs to be centered at the aimed value and the variance of the characteristics needs to be reduced to minimize loss of society. A form of Loss function that Taguchi defines is Signal-to-Noise ratio (S/N): SIN = -10 log(V) (3-2) This form also represents a nominal-is-best situation, yet evaluates the variance of the performance only. The S/N ratio consolidates several repetitions of experiments into one value which reflects the amount of variation present. In the case of this research, the nominal value of the quality performance, the lateral spread, does not always need to get an aimed value. Thus the S/N ratio shown in Equation 3.2 is the appropriate form of the Loss function. 3 Parameter and Tolerance Ds Taguchi's method incorporates these objective functions into a strategy found in design of experiments. Taguchi calls this procedure parameter design Taguchi has devised a technique that combines experiments using orthogonal array (OA) and S/N ratio studies to experimentally optimize for robustness, Table 3.1, quoted from Ross (1988), illustrates the design of experiments to be carried out for a case with seven control factors and three noise factors. For each combination of noise factors laid out on the outer OA, there will be eight trials in the inner OA. Therefore, there are 32 trials necessary in total. ‘Taguchi put the control factors into four classes listed below: Class I: Factors which affect both performance mean and variation Class Ii: Factors which affect performance variation only Class II: Factors which affect performance mean only Class IV: Factors which affect nothing19 Inner/Outer OA Parameter Design Ross (1988) p.191 Table 3.1: 2, Nine factor clas 1v a ge] macaacan ‘Conia! fstor Ross (1988) p.176 contol ttor Classes of Control Factors CContaltetor Figure 3.20 The parameter design strategy is to select the proper levels of class I and class II 10 reduce variation and class IIT to adjust the mean to the target value. Class IV may be set at the most economical level since nothing is affected, Figure 3.1 shows example plots for the four classes of factors. The approach is to move the class I and/or class II factors to flat regions (low sensitivity) to minimize performance variation. The remaining factors are to adjust the performance mean, For significant factors, three-level designs can be applied 10 investigate the possible non linearity. However, if significant interactions are present, it will be impossible to classify the control factors easily. One might need to resort to regression models to locate optimums. 3.1.4 Previous Work in Robust Design Many researchers have studied the Taguchi method and its extensions in mechanical design for robustness. Kackar (1985) and Hunter (1985) promoted the application of statistical experiment and parameter design to quality control. d’Entremont et al. (1988) adopted Taguchi’s concept of quality loss and developed a nonlinear programming code. Their goal was to minimize performance variability when design is constrained to have target performance. Sundaresan et al. (1989, 1991) adapted the Taguchi's method and incorporated a Sensitivity Index in the optimization procedure to seek a robust optimum. Another challenge in robust design is dealing with constraint uncertainties. Almost all the design parameters afe subject to manufacturing variations and constraints. Conventional actively constrained optimum may not be statistically feasible. Sundaresan er al. (1993) compared the efficiency of three different methods which incorporate variations in constraints. Yu ef al. (1994) dealt with manufacturing errors that affect design variables with specific characteristics, Manufacturing Variation Patterns (MVP).21 3.2 Outline of the FEM Code TASKS This research used the FEM computer code TASKS (Three-dimensional Analysis of Shape-rolling as a Kinematically Steady-state Process) developed by Engineering Research Centet for Net Shape Manufacturing at The Ohio State University, as the experimental tool. TI section explains the outline of this software (Kim et al, 1991). 3.2.1_Background of TASKS The shape rolling process includes such compiex 3-D deformation that many researchers primarily focused on empirical models. In late 1980's when numerical analysis of rolling process was becoming leading method along with the development the computer systems, several techniques for the three-dimensional finite element simulation of rolling were developed (for instance, Mori et al., 1989). The practical application of this method, however, is limited mainly because of large amount of computation required and the complexity of data preparation. To overcome these difficulties, Kiuchi er al, (1987) developed a "complex element method" (Kim et al., 1991) where the three-dimensional finite element method and slab method are combined to simulate a shape rolling process. In their method the force balance in the rolling direction was considered repeatedly. 3.2.2__Development of TASKS Kim et al. (1991) developed a new three-dimensional computer-aided simulation by further simplifying Kiuchi's method. In this code TASKS, the two-dimensional rigid- plastic finite element method, used for the generalized plane-strain condition, is combined with the slab method (FSEM, finite and slab element method) resulting in reduced amount of computations without losing accuracy obtained in the 3-D simulations. The generalized22 plane-strain condition assumes a uniform strain in the perpendicular direction to the plane. The basic assumption of the FSEM is that the longitudinal velocity or strain rate is uniform over any cross-section perpendicular to the rolling direction. That is, a plane remains as a plane during deformation. Then they took a slice (or a slab element) of the workpiece and applied the 2-D rigid-plastic finite element method to the plane of the slice. Figure 3.2 shows the basic concept of the FSEM. Details of the numerical approach can be found in the reference (Kim et al., 1990). ation_and Kim er al. (1991) applied TASKS to three cases of flat rolling, shape rolling of a simple H section, and rolling of a practical H-beam section. Alll of the results showed good agreement with those obtained from complete 3-D simulations and/or experiments. Uy, Incoming veleity Uy Outgoing velocity S_ Backrension » Sy Frontenson Veet jet 1 set’ Longing ain 4) Gawhotihe rth Figure 3.2: Application of FSEM to the Shape Rolling Process (Kim et al., 1991)23 3.3 Concept of Parameter Setting Lateral spread, or the change in stock width by rolling, is an important parameter in tracking rolling quality. In general, we can neglect spread in sheet rolling, since elongation is dominant at the condition of high w/h ratio in rolled stock. On the other hand, in shape rolling whose 1/h ratio is usually low, spread is one of the most important factors in rolling with significant impact on the product profile. The complexity of three dimensional material flow prevents any simple prediction of the spread. Hence, most of the roll pass designing is due to empirical formulae developed over the years. On the basis of these previous development, this section discusses the concept of parameter setting for this research approach. 3.3.1_ Factors Affecting Lateral Spread The factors affecting spread have three main categories + (1) Geometric factors: Geometric variables involved in the rolling process, such as initial width to thickness ratio of the workpiece, shape of the groove, roll diameter. (2) Frictional factors: State of surfaces of the rolls and of the material being rolled. The condition of the scale becomes another governing factor in the case of hot rolling, (3) Material factors: Factors affecting the yield stress of the material, ie., strain rate in hot rolling, rolling temperature, and material composition. 3.3,2_ Geometric Factors Factors in this category have such pronounced affect on spread that many researchers studied this category and derived a variety of formulae. Of the several geometric24 parameters involved in hot rolling, it is generally agreed that the following four factors exert a significant influence on spread; (1) the ini thickness (/;) (2) the final thickness (ht) (3). the ini width (w,) (4) the work roll radius (R) Helmi et al, (1968) conducted experiments covering a very wide range of ratios wy/h, R/h, and (hy- hW/h, in flat slab rolling, and developed a formula : we yt S=09 ie oy (G3) un) Sheppard e¢ al. (1981) analyzed the mechanisms of lateral spread by employing the concept of side-fold and bulge (Figure 3.3). According to their study, the width of slab in contact with the roll surface (side-fold) increased much more rapidly than did the concavity of the edge profile (bulge), and the geometric variable R/h, had a pronounced effect, while Helmi et al. (1968) neglected this factor as affecting very little. One of their conclusions is that any empirical formula which does not include each of w,/h,, R/h and w//[R(h,- h,) PS is imprecise. Their formula is as follows : before rolling after rolling Figure 3.3: Concept of Spread by Side-fold and Bulge Sheppard et al. (1981)25 ws _f RV (wm V2 (x (as7sTy 028850.) Sy = me = ees 0.032Ty - oon] x (satan) x (=) (3-4) where Ty is the rolling temperature (°C), Here, the more direct approach of using the width strain S,, was suggested. In rod rolling, the deformation phenomena are more complex than flat rolling. ‘Therefore the spread prediction has been difficult and fewer developments were reported. Among them, spread calculation by Lend] (1948 a,b) and Moses (1959) are typical studies and they are still in practical use even though they were developed several decades ago. Shinokura and Takai (1982) experimentally investigated the spread phenomena of mild steel rods in four types of Square-Oval, Round-Oval, Square-Diamond and Diamond- Diamond. In their work, deformation of rolled stock was translated into equivalent rectangle as shown in Figure 3.4, in order to apply the concept of a flat rolling formula to groove rolling. ‘Their formula is; — W2—W1 «9.93 VRnlhim hom) Fie G5) w) w)+05xh; Fy where Ryr hjns and /zy are mean roll diameter, mean height of material, and mean height of groove, respectively. Fy/Fo represents fractional reduction of area as shown in Figure 3.4, It can be found that this formula consists of the items related to the geometric factors discussed before, i.e., w/h,, R/h, and w//{R(h,- h,)}®5, although the forms are quite different from former studies in flat rolling. This formula is so simple that Japanese rod manufacturers often use it for practical rolling analysis. Kennedy er al. (1983) developed computer code RPDROD based on this formula. It should be noted here that the third factor, w /[R(h,- h,)]°5, can be expressed as: w/[R(hy~ h)J> = [h/R]POS [hf hy- hz) [wy] 3-6) which suggests that geometric factors consists of w/h,, R/hy and (hy- hilt.26 groove Figure 3.4: Eq ent Rectangular Transformation Method (Shinokura et al., 1982) ‘As a conclusion of this part, the following non-dimensional geometric factors significantly affect the lateral spread: (1) initial width / thickness ratio [w/h,] represents the physical constraint of metal flow. (2) roll radius / initial thickness ratio [R/h,] represents the effect of side-fold. (3) reduetion in height ((h- &)/h;1 represents the effect of bulge. 3_Frictional Factors Some degree of confusion appears to exist in the effect of friction on spread. El- Kalay et al. (1968) found that, for a given reduction and geometric condition of flat rolling, smooth rolls provided a higher value for the spread coefficient than rough rolls. However,27 in the most case of tod rolling, it is a common experience that the better the lubricant the less the spread. The results of computer simulation by Sevenler et al. (1986) explained this, contradiction employing the idea of bulge which depends on geometric factor. In Sheppard's experiments (1981) whose R/h, value was 5.0 in minimum, side-fold showed a significant effect on spread, On the other hand, El-Kalay et al. (1968) conducted experiments under the conditions of R/h,=10.0, which can be supposed that side-fold was not appear and, instead, the spread of initial contact surface was the dominant factor in total spread. This idea should also explain the contradiction in the effect of roll radius (R/h,) between Sheppard et al. (1981) and Helmi et al. (1968) discussed in Section 3.3.2 before. The discussion above suggests that under the condition of red rolling whose R/h, value is relatively low, sometimes as low as 3.0 in existing cases, the higher the friction coefficient the larger the lateral spread. Obviously, in groove rolling this tendency should be more significant because of larger effect of side-fold. In general, under the condition of hot stee! rolling when no lubricant is applied, the friction coefficient is usually m=0.7~1.0 (Altan et al., 1983). 3.3.4 laterial ictors Under experience-based discussion, material factors may have only a little influence on spread, Sheppard et al. (1981) even concluded that material properties and strain rate had almost negligible effect. However, their formula suggests that flow stress, expressed by the temperature factor, would have some effect on lateral spread. Further, Mauk et al. (1982) found that the spread in a hot rolling pass was defined as the function of the mean flow stress during the deformation. Raghunathan et al. (1989) employed the material factor, i.e., flow behavior, through the temperature compensated strain rate Z, Zener-Holloman parameter. They conducted28 over 120 flat rolling tests using aluminum alloys and compared the collected spread data with those predicted by the two existing formulae, Helmi et al. (1968) and Sheppard et al. ( Ea R 08 n=) [= A) \hy 35 ( ZY RY?( wy -){ 2.72-.125in— | —| | AE “ ( FL) (el) where Z : Zener-Holloman parameter (s-!) (1981). Their new formula is : =71 ARI, AE Z=éexp— = Alsinhaoy" G-8) P Gp Al y ) A, on: material constants AE : activation energy G = gas constant T : absolute temperature (K) By using the function Z/A, which combines the temperature, roll speed (w), and material characteristics, the flow stress under the appropriate deformation conditions have been introduced implicitly into the spread function. asic Concepts of Parameter Settin: (1) Design Parameters Previous studies suggest that w//h,, R/hyand (h,- hy)/h, are the most significant parameters on lateral spread. However, since those parameters are basically appropriate for flat rolling, redesign of parameters are necessary. ‘The basic concepts of the parameter design are following. (A) General Design Parameters : As observed in the study of Shinokura er al. (1982), the three significant parameters of w//h;, R/hyand (hy- h,)/h, should be common factors between flat and shape rolling. Hence, it should be reasonable to directly use them as general design parameters in this research. However, these general parameters should only be in charge of the geometric parts which correspond to flat rolling.29 General parameters assume plain area being in charge of flat rolling. Particular parameters correspond to shaded area being in charge of lateral constraint. Figure 3.5: Concept of General and Particular Parameters B) Particular Design Parameters : A roll pass for rod rolling, basically groove rolling, should have factors that are in charge of constraint in lateral spread of the stock; the geometry of the groove, These particular parameters should be separated from the group of the general parameters which include the assumption of flat rolling. The total design parameters for this research consist of the combination of these particular parameters and the general parameters. Figure 3.5 shows the concept of the general parameters and the particular parameters. Although this example uses an oval pass, the concept would be the same for any patters of groove for rod rolling such as box, square, and round. (2) Process Parameters Among the factors affecting lateral spread discussed in Section 3.2.1, the material factors may be kind of special; they are controlled by external restriction, such as production variety, production rate, capacity of equipment, and so on. Therefore, they do not always have flexibility for roll pass design. The next chapter will investigate how significantly the material factors are effective on lateral spread.30 @) N A process always includes noise factors which cause variance in any measurement or Parameters experiment, Besides Taguchi's grouping of noise factors into three categories (outer, inner, and product noises), these noises can be grouped differently into another set of three categories below in respect of their origin. First category is the process control error, such as variance in stock dimensions, roll gap (caused by roll displacement and roll bending), and roll radius. Some of them may be unexpected process error, while others may be process allowance necessary for production. Second category is the uncontrollable process factors, such as variance in friction coefficient and rolling temperature, These factors are not controllable by nature, though their affect may be very little, The third category is the human error, such as roll gap (caused by setting error) and the angle of material orientation when twisters are used. Although the values of the noise factors depend a lot on the choice of production facili s, this research uses reasonable values based on an existing wire rod mill, with slight overestimation. Quantities of some unmeasureable and/or qualitative factors are based on the author's practical experience of more than ten years in a rolling facility. (4) Quality Parameter Quality parameter, or response parameter, is selected to be the percentage spread; Sp = [(we- w;) / wy] x 100 (%) (3-9) as defined in Chapter II. This parameter directly indicates the magnitude of lateral spread. The target of this research is to determine the design parameters so that the variance in the percentage spread S, would be as small as possible.CHAPTER IV SCREENING OF PARAMETERS Chapter III discussed the three categories of the effective factors on spread; geometric, frictional, and material factors. It makes sense that the geometric factors have the most significant effect on lateral spread among the three categories. On the other hand, frictional and material factors do not directly effect the quantity measure since they are basically invisible. That may be one of the reasons that a detailed study on frictional effect under specific rolling conditions in shape rolling has not been reported in the past. Therefore numerical values of those factors should be included in some way in the model, otherwise the results of simulations would possibly include unknown bias, which might lead this study to a wrong conclusion. ‘This chapter tries to empirically clarify the effect of the frictional and material factors, using practical data and statistical methods of analysis. ‘The results of the study in this chapter will provide quantitative guidelines for the parameter design discussed in the later chapters. 3132 4.1 Basic Methodology of the Screening Experiments Frictional factor, or frictional coefficient (m), is really unknown and complex since it is very difficult to define it by direct measurement, However, it is known that spread and torque are possibly related to frictional effect. This investigation followed three steps to estimate those factors indirectly. (1) Practical data collection The following data were randomly collected from a practical rolling process; (a) geometry of incoming material (height and width) (b) geometry of outgoing material (height and width (©) motor torque (d) rolling velocity (rpm of the roll) (©) rolling temperature (0) tonnage of the rolls Fifteen sets of data were collected in an oval-square and a square-oval pass sequence during a period of 2 weeks. Consequently, the tonnage (random variable) varied from 50 to 2,400 tons. Figure 4.1 shows how to obtain the profiles of the on-line material from a practical solling process. By pushing a piece of wooden board against the edge of the material, the board is burnt and gouged since the material is hot and running, then the shape of the material is “printed” on the board. This method is called “wood printing”. Width of the stock will be obtained by fitting the “wood print” on the real-sized drawing of the grooves used for the corresponding rolling pass. Height of the stock should be calculated from the designed depth of the grooves.33 wood board Figure 4.1: Wood-Printing Method to Obtain the Rolling Profiles Rolling motor torque Tis calculable from the power of the mill motor as; Ty = PEEVE emmy @1 Nu where V is the voltage (volts), / is the current (amperes), Ny is the revolution of the motor (eput), and i is the total gear ratio of the reducers. This equation represents the total torque for the upper and lower rolls. It includes the mechanical loss of the power transfer such as reducers and couplings, since this method is not a direct measurement of the rolling torque. (2) Simulation FEM code TASKS computed lateral spread and torque (which corresponds the collected data (b) and (d), respectively) of the corresponding rolling pass under each condition (data from (a) (c) (e) and (f) ). There were two unknown parameters in this simulation work; frictional coefficient (m) and roll wear. In this step, it is assumed that; * Frictional coefficient (m) would fall between 0.5 and 1.0. + Roll wear did not take place during the on-line life of the rolls,34 about 1:3, 900°C about 2" sq., 900°C 1.41). Therefore, the alternate hypothesis is rejected. This t-test suggests that the means of the two conditions are not different. That can lead to the conclusion that the material factors, the carbon content and temperature, does not affect the lateral spread in an aval-square pass. 1.04~ NeIs 1.0d~ N=I5 1.02- mean=0.960 1.02~ mean=0.968 1.00- s=0.0293 1.00- s=0.0326 © 0.98- $ 0.98- 2 o96- F o.96- $ 0.98- $ 0.94 0.92~ 0.92~ 0.90- 0.90- 0.88- 0.58- o 1 2 38 4 5 6 o 1 2 38 4 5 6 (a) High-carbon, 900°C (b) Low-carbon, 1100°C Figure 4.11: Distribution of ws/wa (Oval-Square Pass) (a) High-carbon steel, 900°C (b) Low-carbon steel, 1100°C read. -e-Ovi ass Figures 4.12 (a) and (b) show the distribution of ws/va in the square-oval pass, in the original conditions and the conditions for comparison, respectively. It seems, again, that there is no difference in the spread index, ws/wa, between the two conditions. In the same way, the hypothesis testis following49 Ho: i= hs. Hy: My #M2 (4-8) where 4) is the mean under high-carbon, 900°C condition, {12 is the mean under low- carbon, 1100°C condition. 1; = 0.941, 12 = 0.944, The sample-variance values under those conditions are $,? = 0.000666 and $2? = 0.000625, respectively. Then fg value is ; "= at BoOOES =O? “ 1 BS 1,699 (30.323), the alternate hypothesis is rejected. Since to0s,2 This t-test suggests that the means under the two conditions are not different. That can lead the conclusion that the material factors, the carbon content and temperature, does not affect the lateral spread in an square-oval pass, either. 1.20~ 1.20~ N=I5, 1.00~ 1.00~ mean=0.944 0.98~ 0.98~ s=0.0250 & 0.96~ @ 0.96~ 20.5 Fost 8 0.92 $ os 0.90 0.90~ 0.88- 0.88~ oe [yy 0.86~ o 12 3 4 5 6 o 1 2 3 4 8 6 (a) High-carbon, 900°C (b) Low-carbon, 100°C Figure 4.12: Distribution of ws/wa (Square-Oval Pass) (a) High-carbon steel, 900°C (b) Low-carbon steel, 1100°C Material Factors on Torque val-Square Pass Figures 4.13 (a) and (b) show the distribution of 7s/Ta in the oval-square pass, in the original conditions (high-carbon steel, 900°C) and the conditions for comparison (low- carbon steel, 110°C), respectively. This time, it seems that there is a large difference in50 the torque index, 7s/Ta, between the two conditions. In the same way, the hypothesis test is following : Ho: Mi = Mz vs. Hy: My # hz (4-10) where jl) is the mean under high-carbon, 900°C condition, ji is the mean under low- carbon, 1100°C condition. 11; = 9.857, U2 = 0.515. The sample-variance values under those conditions are $2 = 0.0153 and 00376, respectively. The to value is ; 0.857 = 0.515 = = 10.1 - o 135 0.00376 any 75 7 a5 Vous IS where degree of freedom is 29. From a ttable, fa95,29 = 1.699 (<10.1). ‘Therefore, the null hypothesis is rejected. This t-test suggests that the means under the two conditions are different. That can ead to the conclusion that the material factors, the carbon content and temperature, significantly affect the rolling torque in an oval-square pass. The discrepancy is, statistically, about 34%. 1.10- Nas ooo. mean=0.515 3=0.0613 0.80- § 0.70. 2 0.60 is] a 0-40~ s=0.116 0.30- : oO 2 4 6 8 10 O 2 4 6 8 10 (a) High-carbon, 900°C (b) Low-carbon, 1100) Figure 4.13: Distribution of 7s/Ta (Oval-Square Pass) (a) High ‘bon steel, 900°C (b) Low-carbon steel, 1100°CSL Material Factors on Torque juare-Oval Pass Figures 4.14 (a) and (b) show the distribution of 7s/Ta in the square-oval pass, in the original conditions (high-carbon steel, 900°C) and the conditions for comparison (low- carbon steel, 1100°C), respectively. This time, it seems that there is a large difference in the torque index, Ts/Ta, between the two conditions. The hypothes test is following : Ho: Hr = He vs. Hy: My # Hz (4-12) where # is the mean under high-carbon, 900°C condition, j12 is the mean under low- carbon, 1100°C condition. jt; = 1.098, uz = 0.665. The sample-variance values under those conditions are S)2 = 0.0159 and $2? = 0.00487, respectively. The fg value is ; = 00s, -1 ‘°° T0139 , 0.00487 17 ae Vs 5 where degree of freedom is 29. From a t-table, fo.0s. 29 = 1.699 (<11.7). Therefore, the null hypothesis is rejected. This t-test suggests that the means under the two conditions are different. That can lead to the conclusion that the material factors, the carbon content and temperature, significantly affect the lateral spread also in an square-oval pass. The discrepancy is, tistically, about 43%. Eo. £ F 0.80 _ . 0.70~ Nel Sete mean=1.098 ee s=0.126 O 2 4 6 8 10 oO 2 4 6 8 10 (a) High-carbon, 900°C (b) Low-carbon, 1100°C Figure 4.14: Distribution of Ts/Ta (Square-Oval Pass) (a) High-carbon steel, 900°C (b) Low-carbon steel, 1100°C4.6 Summary of the Screening Experiments This chapter discussed the effects of frictional and material factors on the lateral spread and the rolling torque. In conclusion, Figure 4.15 in the next page shows whether and how those uncontrollable factors affect these output parameters. (%) Effect {Effect on Spread Roll Pass Pattern ae 0-8: Oval-Square $-O : Square-Oval Effect (%) =[ Ts/Ta(higher factor) - Ts/Ta(lower factor)}x100 or [wshva(higher factor) - wshva(lower factor) x100 Figure 4.15: Effect of the Frictional and Material ParametersCHAPTER VY APPROACH TO ROBUST DESIGN OF A SQUARE-TO-BOX PASS ‘As stated in Section 2.2, a box pass usually plays a role of an oval former at the very first pass of a rod rolling sequence. The product of this pass is going to be the input material for the following oval pass, which is generally loose in lateral constraint. Therefore the geometry of the outgoing stock from a box pass must provide the least variance in the parameter of w;/h;, which directly affects on lateral spread, for the next oval pass. This chapter focuses on the design of a box pass to get the optimum design for reducing the variance in lateral spread. 5.1 Parameters for Robust Design 5.1.1 Controllable Design Parameters On the basis of the discussion in Chapter IV, the design parameters should have two categories; general parameters and particular parameters. 5354 Figure 5.1: Geometry of a Box Pass No further explanation should be necessary for the general parameters. It includes the following three non-dimensional parameters: (1) Input Billet Width / Billet Height Ratio (wwy/h7) (2) Roll Diameter / Billet Height Ratio (2R/h,) (3) Height-Reduction Ratio (l12/hy) Particular parameters should define how narrow the groove width of this pass is. On the basis of this idea, the following three parameters are appropriate For definition of the geometry: (4) Bottom Wiath / Billet Width Ratio (w/v) (5) Comer Radius / Billet Width Ratio (2r/w7) (© Relief Angle (a) Figure 5.1 shows the geometry and the parameter definition of this box pass.55 5.1.2 Uncontrollable Design Parameters Quantitative values of the noise factors in practical rolling lines much depend on the characteristics of the mill, that is, case-by-case. The following discu: mainly based on the practical example of an existing steel wire rod rolling line. (1) Variance in Input Billet Geometry (w;/h;) = In the first rolling pass, billet geometry deviates because of breakdown-rolling allowance and billet treatment (grinding). With a square billet, it is common that industries control the tolerance of measurement on each side to within +2%. Consequently, »)/hy gets +4%. (2) Variance in Roll Radius (R) : Rolls are re-ground by turning after rolling assigned amount of products to remove roll surface defects such as flaw, crack, wear, and so forth. That machining makes the diameter of the rolls smaller with new contour of the groove, as shown in Figure 5.2. Although it depends on the several process factors, usually around 14~15% of the diameter in a newly purchased pair of rolls will be effective, that is, reduced during the life of the pair. In this reason, the design measurement R includes the noise of +7% in maximum. ‘New groove contour after turning SN Old groove a — with defects Figure 5.2: Outline of the Roll Re-grinding56 5.1.3 Uncontrollable Process Parameters According to the screening experiments discussed in Chapter IV, there are two factors that affect the rolling profile of the square-to-box pass. Here, it is assumed that a box pass is equivalent to a square pass in its characteristics of rolling profile: (1) Effect of roll wear : It directly affects the lateral spread by 6.4%. (2) Effect of material: It affects the rolling torque or the roll separating force by 34.2%, that indirectly affects the lateral spread because of the roll displacement. Furthermore, there is another factor that significantly influences the roll separating force: (3) The number of the rolling strands in a multi-strand mill. For example, when the all of the 4 strands are working, the roll separating force is four times as large as that when only one of the strands is working. tis interesting that all of the three process factors can be translated into the variance of the groove height hz. The following discussion will aim to quantitatively find the influence of these factors on h2. (1) Effect of roll wear Going back to Figure 4-3, one can observe that ; * the regression curve of m=0.5 is almost horizontal, and + the regression curve of m=1.0 deviates about 0.06 at the tonnage=2500 from that of m=0.5. The two regression lines should have been the same because they had the common interception value of 0.926. The discussion in Chapter IV assumed that the discrepancy of the two lines had come from the unexpected roll wear. ‘Then, it should be a reasonable idea that the roll wear, geometrically expressed as the deviation in the depth of the groove, can be estimated by finding the groove height that will make the two regression lines57 statistically identical te each other. In Figure 5.3, the plot indicated by the blank circles is the virtual data seties of m=1.0 proportionally reduced until it becomes statistically identical to the data series of m=0.5. The new virtual data series was calculated by following way; ws/wa( virtual) = [7*wshva(m=1.0) + 9*ws/wa(m=0.5)1/ 16 (6-1) That is, the data series of m=1.0 will be statistically identical to m=0.5 when the discrepancy between the two series was reduced to less than 7/16. This ratio 7/16 is the upper limit for the identity achieved by several trials and errors of t-tests. Figure 5.3: ws/wa Figure 5.4: 1.05 virtual ° 500 1000 1500 2000-2500 tonnage (ton) Virtual Data of ws/wa That Is Identical to the Series m: wear 0.996 ma 2.01 1.00 0.99 0.98 ° ° ° ° 97 96 -95 0. 94 0.56 0.58 0.60 0.62 0.64 0.66 hat original 77 Estimation of the Depth of Wear for the Maximum Tonnage58 Figure 5.4 shows the result of the estimation of roll wear depth using the data point of tonnage=2442, the right-end data group X in Figure 5.3. The horizontal axis parameter indicates hy/h), which is originally 0.577. (Note that hy is constant in this case.) Here, the target value of ws/wa is 0.963, the corresponding reduced value calculated by (0.938x9+0,996x7)/16. This estimation suggests that ; + When hy/h, increases to 0.615, ws/va decreases to the target value 0.963, * The increment of o/h; is 0.038 (= 0.615 - 0.577) or 7% of the original value (0.577). This estimate 7% should be equivalent to the depth of wear, .€., noise value in #2 by wear. However, in the real world, occurrence of wear is partly predictable. Operators try to remove the influence of wear by adjusting the roll gap, although it is impossible for them to always watch and adjust it. Considering the real condition, it may be appropriate to take into account the 50% of the estimated value of wear as the noise range. Thus, the noise value affected by wear in h2 should be 3.5%. & 1.016 E104 J NE Beocroove Zio NF rts = 1.010 2 1.008 Range "A" : Deviation by B 1.006 material factors (£17%) g 2004 Range "B” : Deviation by 3 1.002 the number of rolling strand 2 3 & 2.000 © 100-200 300 400. 500-600 Roll Separating Force (ton) Figure 5.5: Groove Height of a Box Pass and the Roll Separating Force (Primary Data from Nippon Steel Corp.)59 (2) Effect of material ‘As stated before, material factors affect the lateral spread as the result of roll displacement, or roll jump. It depends on the mill spring constant, which is particular to the facility; rigidness of the roll housing, diameter and material of the rolls, and so forth. Figure 5.5 shows an example of the relationship between the roll separating force and the groove height in the first box pass of an existing wire rod mill. (Since this mill has four strands, the range of the roll separating force is as wide as 500 ton.) In the figure, range "A" shows the deviation of the roll separating force by the material factors, "low-carbon in 1100°C" versus "high-carbon in 900°C", found to be 34% or +17%. The plot suggests that the deviation in the groove height by the material conditions is less than 0.5% of the initial setting of the groove height h2. (Although this value depends on the mill spring constant, this thesis uses the particular case on the basis of this existing case to represent this factor.) ¢ falling direction rolls \ + \ rolling by 4 strands discharge only 1 strand active only 2 strands active Figure 5.6: Mechanism of the Strand Factor (Case of 4-strand) (3) Effect of the number of rolling strands On the other hand, the deviation of the roll separating force by the number of rolling strands, 1, 2, 3 or 4 in this 4-strand mill, is quite large as the range "B" in Figure 5.5. This factor comes from the time Jag between the strands in discharging billets from the60 reheating furnace. The number of rolling strands which are actually rolling the billets varies; basically four, but sometimes one, sometimes two or three, as shown in Figure 5.6. That variation makes the variance in roll separating foree. The plot suggests that the deviation in the groove height by the strand factor is about 1.0% of the initial setting of the groove height hz. (This value also depends on the mill spring constant.) Figure 5.7 shows the uncontrollable process noise parameters and their influences on ha/hy discussed in this section 5.1.3. The figure suggests the design parameter ha/h; includes the noise of 2.5% affected by roll wear, the material effect, and the strand effect. wear 3.5% material : 0.5% initial setting : 100% ‘strand effect : 1.0% Figure 5.7: Process Noise Factors and Effects on h (Square-Box Pass) 5. Quality (Output) Parameter Percentage spread, Sp, is the quality parameter as defined in the Equation 2-5; Sp= [lov - wy) /w1]x100 (%) (6-2) where each variable is defined in Figure 5.8. In this case of a square-box pass, w should be the width on the center line, for the maximum width Wimax may include the error that ‘comes from the isothermal simulation. ‘Table 5.1 is the summary of the parameter design discussed in this section 5.1.61 Figure 5.8: Parameter Definition of the Deformation Table 5.1: Parameters Defined for Experiments Category inition Symbol 1. Controllable Parameters 1.1 billet width /billet height —ws/hy (Design) 1.2 roll diameter /billet height 2R/h, 1.3 reduction ratio hefh, 1.4 bottom width / billet width —w,/w, 1.5 comer radius {billet width 2r/w, 1.6 relief angle a 2. Uncontrollable Parameters 2,1 billet width /illet height A(wy/h,)_: 44.0% (Noise) 2.2 roll radius AR 2 47.0% 2.3. groove height Ah, 112.5%62 5.2. Design of Experiments One of the most important concepts in Taguchi's theory is the design of experiments in fractional orthogonal arrays. This section discusses the experimental design on the basis, of the parameter definition and Taguchi's concept of the orthogonal array. AN Design Paramete, Table 5.2 shows the controllable factors and the levels of each value, defined on the basis of conventional design ideas. The three-dimensional deformation in this process seems so complex that non-linear correlation of spread against those factors may exist. Therefore, three-level experiments are appropriate for this case. In each factor, the nominal level represents approximate value of an existing design. Table 5.3 is the orthogonal array for this case. Assuming no interaction between those factors, an L18 orthogonal array was applied. juter_Arra’ loise Paramete Based on the discussion in Section 5.1, Table 5.4 shows the noise parameters and the levels. Assuming the linear affects of noises on the quality parameter, a 2-level experiment design was applied for those noise parameters. Table 5.5 is the corresponding L4 orthogonal array for noise parameters (outer array). 5.2.3 Simulation Experiments Seventy-two (18x4 =72) simulation experiments were conducted using the finite element computer code TASKS 2.0 developed by the ERC of Net Shape Manufacturing, the Ohio State University (Kim et al, 1991, Lee et al, 1992). Since deformation is only the63 point of interest, an isothermal simulation method was applied to save computation time. That is, temperature effects were neglected. Table 5.2: Levels of Controllable Factors (Square-Box) Factor (A) w/h, (B) 2R/h, (C) hyp, (D) w/w, (E) rh (F) a Examined Levels Low 0.60 2.50 0.70 0.80 0.60 30.0° Nominal High 1.00 1.40 3.50 4.50 0.75 0.80 0.90 1.00 0.70 0.80 35.0° 40.0° Table 5.3: L18 Orthogonal Array for Controllable Factors (Square-Box) Run# EMEZZZCCCREEZAZZOoe RACRACRAZCRACMACMAM py c ZOMOMAAZC MOMMA ZO CO Ome ZeRZC EE Zoe Ze ZCERAZCOMAZCEOLZEZO my MZCZCRCGZORAZOEZC hy Low N: Nominal H: High Table 5.4: Levels of Uncontrollable Factors (Square-Box) Factor (dA) A(w,/h,) (dB) AR (dC) Ah; Nominal 0 oo Applied Levels Low High - 4.0% + 4.0% - 7.0% + 7.0% - 25% + 25%64 Table 5.5: L4 Orthogonal Array for Uncontrollable Factors (Square-Box) ac Runit aun 5.3 Results of the Experiments dA L L H H dB L H L H come L:Low H: High Table 5.6 shows the values of the percentage spread S, for 18 levels of experiments on the L18 orthogonal array. Since the outer array for the noise parameters is L4, each run has four repetitions. (See Section 5.3.3 for the definition of S/N.) Table 5.6: Results of the Experiments Using TASKS over L18 OA (Square-Box) Run#t Percentage Spread Sp (%) 1 8.129 7.649 5377 5.621 5.582 4073 1581 1.557 9.762 2.272 11.309 9.633 3,001 4.896 8.197 1.274 4.994 4131 2 1.166 5.475 4.247 5.455 3.930 4.050 3.037 1.057 5.236 1.627 10.069 8.421 3,006 3.230 6593 1.615 4.499 ain 3 9.040 7.947 5.992 7.100 7.306 6.166 7.530 4.330 7.645 2.200 10.987 9.138 sms 6.545 10.135 5.440 6.746 7.582 4 13.211 9572 8.573, 9.945 8.381 8.575 7.243 6.040 8,968 5.607 13.694 13.822 TAR 7.764 12.506 6396 9.620 10.309 2.508 1.684 4.832 2.079 1.956 2.149 2.993 2.354 1.722 1.810 1.545 2.430 2.073, 1974 2.550 2.616 2.314 2.984 SIN 6.333 “8.352, -7.287 9.494 -7.985 4.528 6.358 -5.826 6.644 9.524 “7.437 4.722 “5.155 7465 Table 5.7: ANOVA Summary on Percentage Spread (Square-Box) Source df. w/hy 2 2R/hy 2 hh; 2 wow 2 2r/w1 2 a 2 error 59 Total 71 5 Analysis of Variance 88.52 50.43 186.13 39.25 8.81 9.51 276.22 658.87 MS. 44.26 25.22 93.07 19.63 4.40 4.76 4.68 E 9.45 5.39 19.88 4.19 0.94 1,02 at * + : Atleast 99% confidence *: Atleast 95% confidence Table 5.7 shows the analysis of variance in this experiment. This table suggests that (1) why, 2R/hy, ho/h;, and wp/w; have significant effect on the mean performance of the percentage spread S,, (2) The other parameters have very little effect. 5,3,2_ Regression Analysis ‘As a guideline for the process design, one should grasp the regression of the percentage spread and the reduction of area on these independent parameters. This procedure is an important step for the total process design as well as the roll pass design, thus many researchers have developed a number of empirical formula. This study developed simple regression formula from the experimental data using the statistical software MINITAB. Table 5.8 (a) and (b) show the regression analysis of Sp and Ar, respectively.66 Table 5.8: Regression Analysis (Square-Box) (a) Percentage Spread (S,,) Predictor Coet Stdev t-ratio P Constant 43.369, 5.642 7.69 0.000 w1/h1 -3.3851 0.7724 4.38 0.000 2R/h1 0.9474 0.3098 3.06 0.003 h2/h1 -40.487 6.197 6.53 0.000 ub/wi 7.109 2.784 255 0.013 s = 2.141 Rosq = 53.48 R-sq(adj) = 50.6% (b) Reduction of Area (Ar) Predictor Coet Stdev t-ratio PB Constant 101.218 6.608 15.32 0.090 wi/ht 7.3375 0.8649 +43 0.000 h2/hi -76.909 6.938 :08 0,000 wb/wi -24.401, 3.109 +85 0.000 a -0.15092 0.06919 18 0,033 s = 2.397 Rsq = 78.8% Resq(adj) = 77.5% (1) Percentage spread The best simple regression model of the percentage spread (S,) is Sp = 43.4 - 3.39%w/hy + 0.947*2RMhy - 40.5*hy/hy - 7.11 wp/wy (5-3) (2) Reduction of area The best Ar = 101 + 7.34*w//hy - 76.9*hz/h; - 24.4* wphw} - 0.15 1*a (5-4) imple regression model of the reduction of area (Ar) is Robust Design for Consistent Lateral Spread ‘The most important purpose of this series of experiments is to find the most robust design for the response S,, i.e., minimum variance. Here, for evaluation of each run of the inner array with repetition due to the outer array, Taguchi defined S/N ratio as follows ; YN = -10*logV (dB) (5-5) where V is the variance within each run.S/N (dB) S/N (dB) & 3 § z mean of Sp Figure 5.1 8 8 1 6 5 67 | | K/4 °° Taha Zales wales rr rr Parameter / Level “00 S aN fa ¢ °° | Trea aed k LAH LN a GN # Parameter / Level Mean of S/N in Each Level and Parameter (Square-Box) -00 (a) 00 oo 00 00 00 00 wi fas 2Rja1 na jat LON # LON # LNW Parameter / Level 00 2) T 00 00 So 00 00 00 oo L_ Lede e/a kb LN oH LON # LON H Parameter/Level Mean Performance of Sp in Each Level and Parameter (Square-Hox)68 Figures 5.9 (a) (b) show the plot of S/N with respect to each level of design parameters. The plotted value is the mean of S/N from all the experiments that used the particular levels of the parameter. These plots suggest that there is not an outstandingly effective parameter on robustness, However, w)/hy, 2R/hy, and wi/w; are relatively effective among these factors. On the other hand, Figures 5.10 (a) (b) show the mean performance of S, with respect to each level of design parameters. The plots suggest that w/h), 2R/hy, ho/h, and wyAwy have significant effects on the mean performance of Sp. According to the definition by Taguchi discussed in Chapter III (Figure 3-1), these six parameters can be classified into the four groups listed below; ClassI: wj/hy, 2R/hy, and wy/w; affect both performance mean and vatiation. Class II: No parameter affects performance variation only Class II: p/h affects performance mean only. Class IV: 2r/w; and a affect nothing. 5.4 Comparison with Empirical Knowledge and Common Sense One may be able to optimize the groove geometry now by taking a level which shows the highest S/N ratio in each parameter using Figure 5.9. However, practical rolling processes include restriction, i.e. real boundaries. It is necessary here to interpret the robustness trends and find the optimum parameter design with obedience to the real boundaries.6 (b) groove contour S/N (dB) rolled material Wey! Wry] eFr = We/Wr*100 (%) o 20 40 60 80 Edge Filling Ratio (eFr,%) Figure 5.11: Correlation of S/N to Edge Filling Ratio (a) Correlation (b) Definition of Edge Filling Ratio 5.4.1 Interpretation of stness Trends Figure 5.11 shows the relationship between S/N ratio and the edge filling ratio, Bach plot is the mean of S/N ratio in each level of the inner array. The horizontal axis indicates how far the material has deformed into the edge part of the box groove. It clearly shows that there is an optimum value in the edge filling ratio around 20%; either larger or smaller filling will hinder robustness. That tendency makes sense because: (1) If the edge filling ratio is too small, the billet has little lateral restriction. (2) If the edge filling ratio is too large, small deviation of the cross section area, caused by the noise factors, can lead to large deviation of the lateral spread. That implies the edge filling ratio can be a criterion for robust design of a box pass. 5.4.2, Examination of Parameter wj/hy This parameter has the most significant effect on variance of spread; the smaller the better. However, an actual wire or bar mill uses billets of wj/h)=/, square billets. The reasons why square is suitable for material are following,70 (1) Axis-symmetry of Products: Usually bar products have round or close-to-round shape. In order to get homogeneous deformation in the process of material to products, material should have axis-symmetric cross section. Round shape may be possible, but has a problem in stability during carriage in the reheating furnace. (2) Freedom in Direction: A square billet can be rolled in any direction, thus orientation of the billets before rolling (during treatment, storage, handling, or carriage in furnace) does not matter. 5.4.3 Examination of Parameters 2R/h) and h2/h; These two parameters include the deformation factors related to each other. ‘Therefore, this section is discussing the two parameters together. (1) Deformation-zone Parameter (A) The parameter A dominates the homogeneity of deformation (Hosford et al., 1993). Ah2/[Rhy- hz) °F (5-6) If Ais too large, only the surface layer of the stock would be deformed and it would cause inbomogenious deformation (overhung, or double-bulge) as shown in Figure 5.12(a). In an extreme case, central defects or even alligatoring might be observed like Figure 5.12(c). (b) (c) Figure 5.12: Results of Non-uniform Deformation (a) double-bulge (b) single-bulge (c) central defect and alligatoring. Mielnik (1991), p.378n (a) (b) 1.05 wit=1.0 © 1.04 | with noises adjusted 3 c 1 & L, v2 gl 3 ay Wax. a Bi st Double-bulge ratio = Wmax /W2 1 0.800 © 1.000 1.200 © 1.400 1.600 A-value Figure 5.13: Correlation of Double-bulge Ratio to A-value (Square-Box) (a) Correlation to A-value_(b) Definition of Double-bulge Ratio Forces Acting on Material during the Deformation Mielnik (1991) p.3782 Figure 5.13 (a) shows the double-bulge ratio against A observed in the experiments. Here, double-bulge ratio = Winax/ W2 (5-7) Where Wmaeis the maximum width after rolling and wis the width on the horizontal center line as defined in Figure 5.13 (b). Figure 5.13 (a) suggests that double-bulge ratio dramatically rises up when A goes larger than 1.0, while it is less than 1% when A is smaller than 1.0. It should be the reasonable conclusion that A < 1.0 is the safe area against the occurrence of double-bulge. (2) Angle of bite The rolls can't draw the material when friction between rolls and the material is too small, Figure 5.14 shows the forces acting on any point along the arc of contact. Material of thickness hy, brought in contact with the rolls at point A, will be drawn into the rolls if the forward force Hy is larger than H,, the backward force. Since Hy = Pysino: and H-= P,cosor, the material will be drawn when Pysiner < P,cosct, or PyP,2 tana. Since L = PyP,, the criterion for the material to be drawn into rolls will be 2 tanot, Here, 11 is the coefficient of friction at the roll-material interface, Experts in roll pass design usually set a, the angle of bite, at 22.5° ~ 24°, which corresponds to p1 of 0.40 ~ 0.45 (Roberts, 1988). wrinkling (a) (b) Figure 5.15: Quality of the Free Edge Surface (a) proper reduction (b) large reduction with wrinklingB strain I billet ‘groove contour Figure 5.16: Strain Distribution on Material Rolled by a Box Groove 6.00 5.50 5.00 4.50 2R/h1 4.00 3.50 Aal. bite-angle=24" 3.00 2.50 2.00 0.66 0.68 0.70 0.72 0.74 0.76 0.78 0.80 0.82 0.84 h2/h1 Figure 5.17: Acceptable Range of the Roll Diameter and Reduction (Square-Box) (3) Surface quality Quality may be a problem of this rolling pattern (square-box). If the reduction is too high , free sides of the billet will get high strain, which may result in wrinkling as shown in Figure 5.15 (b). This wrinkling comes from the uneven strain distribution forced on the material as shown in Figure 5.16. This characteristic, though effective on descaling, is the reason a box pass is applied only at the early stage of a rod rolling sequence. Although no14 quantitative border exists in this feature, experts generally support an empirical line of hafh}>0.7. Figure 5.17 shows the range of 2R/hy and hz/hy that satisfy the conditions discussed in this section, This figure suggests; + o/h; must be larger than 0.7. + 2R/hy must be larger than 3.4. + Larger h2/h; requires larger rolls due to the A criterion (A 3.4 (5-8)5 Keeping this inequality, one should try to select the value of this parameter as close to the nominal value 3.5 as possible. In ideal, Figure 5.9 shows the best recommended value as; 2R/hy = 3.5 (5-9) 55.3 Parameter h2/hy Once 2R/h, is decided, the next step should be the determination of hz/hj. Since this parameter is a Class III parameter, one should consider the A value and surface quality, and the mean performance of Sp. From the discussion in Section 5.4.3, ha/hy must satisfy the following two inequalities; A=hy/[R(hj- hz)]°> < 1.0 (5-10) hah, > 0.7 (5-11) 55.4 Parameter a This parameter belongs to Class IV; the effects on robustness and mean performance are the smallest, Considered with prevention of overfill, a=30~40° should be appropriate. 55,5 Parameter w,/w, Section 5.4.1 developed a robust design guideline; eFr = 20(%) (5-12) where eFr is the edge filling ratio. The following procedure along with this guideline calculates appropriate value of w/w). (1) Calculation of W, W, can be derived using hz and a as; W, =h2/2 *tan(a) (5-13)16 where W, is the width of the edge relief part of the groove, as shown in Figure 5.11(b).. (2) Estimation of w2/w; Equation 5-3 can estimate the after-rolling width w2/w;. This equation contains wy/hy, 2R/hy, and hz/hy as known variables, and wy/w; as unknown va able. That is: w/w) = 1.434 - 0.0339" /hy + 0.00947*2R/h; - 0.405*hy/h; - 0.0711 *w9/wy (5-14) On the other hand, from Equations 5-12 and 5-13, the optimum w/v; should be; w/w) = w/w, + 0.2*(ho/v, )*tan(a) (5-15) (3) Calculation of w/w; Equating 5-14 and 5-15 will derive w)/vy: 1.434 - 0.0339%w/h) + 0.00947+2R/h - 0.405*h2/h; - 0.0711*w9/w =wplwy + 0.2*(hig/w) )*tan(a) (5-16) or 1.34- oon *t) + ons 28) - aan 2) 0. sar ta 4) tan(a) Ay hy hy Ay AW (5-17) 5.5.6 Parameter 2r/w, This parameter belongs to Class IV, and it does not affect the reduction of area, either. Since Figure 5.9(b) suggests that the nominal level may lead to robustness, 2rhw=0.7 should be appropriate. 5.5.7_Example of the Design Procedure The following procedure is an example of a square-box roll pass design, (A) w1/h; is 1.0 since this is the first pass of the process which rolls square billets. (2) 2R/hy has been selected as 3.5 for the ideal design for robustness.1 (3) hafhy should satisfy the inequalities 5-10 and 5-11. 2R/hy=3.5 makes 0.70 < hy/h)< 0.71. Hence, hy/h;= 0.70 is selected here. (4) a is set as 30°. (5) wp/w, is calculated by Equation 5-17 as; wy/w) = 1.34 - 0.0316 + 0.00884*3.5 - 0.378*0.70 - 0.187*0.70*tan30° = 1.00 (5-18) This solution w,/w; =1.00 will provide robustness according to Figure 5.9(b). (6) 2r/w, is determined as 0.7. Table 5.9 shows preferred design parameters and an example design of a square-oval pass. Substitution of these design parameters for Equations 5-3 and 5-4 will provide the following information; (1) The percentage spread Sy is expected to be 7.9%, That is, the square billet whose initial width is 4.0" is expected to have the after-rolling width of 4.3”, (2) The reduction of are Ar is expected to be 25.6%. This value is an appropriate ratio for a box pass. If these values are not preferable in some reason, one should reconsider the Class IL parameter hz/h,, then repeat the same design procedure Table 5.9: Preferable Parameters and Example of Design (Square-Box) Parameter Preferable Value Example of Desig wilhy 1.0 w1=4.0", hy=4.0" 2R/hy 3.5 R=7" hafhy 0.70 ~ 0.71 hg=2.8" (Iig/hy=0.70)" a 30~40° wr) 1.0 2r/w; 0.778 5.6 Summary of Square-to-Box Roll Pass Design Six parameters; w//h;, 2R/h), ho/h, a, wi/w1, and 2r/w; were defined as the design parameters for square-box pass design. The three noise parameters; A(w7/h7), AR, and Ah represent all the process noise factors for a box pass, including wear, material, and the strand effect. Although the trends of S/N ratio was not very clear, the concept of edge filling ratio clearly showed the robustness trends and played an important role as a robustness criterion. On the basis of this criterion and practical restrictions on quality (real boundaries), a robust design guideline for a squate-to-box pass was developed. Asa conclusion, the robust design guidelines for a square-to-box pass are as follows: (A) w/z and 2R/hy + The determination of these parameters may depend on other restricting factors. The preferable values of these parameters are; wyh;= 1.0 (5-19) and 2RMhy > 3.4 (5-20) (2) hz/hy : From the viewpoints of side-wrinkling and double-bulge, this parameter has to satisfy the following two inequaliti Aaha/[R(hi- hz)]°5 < 1.0 (5-21) hyfhy > 0.7 (5-22) (3)a: To avoid overfilling, 30~40° of edge relief angle should be preferable, That is; 301.2), A< 0.75 should be appropriate. (2) Angle of bite This criterion should be the same as that in the case of square-box pass. Experts in 24°, which corresponds to 11 of roll pass design usually set 0, the angle of bite, at 22.5° 0.40 ~ 0.45. strain ni | material groove contour Figure 6.9: Strain Distribution on Material Rolled by an Oval Groove93 (3) Surface quality Since an oval groove contour is closer to flat than a box pass, the strain distribution on the material is even as shown in Figure 6.9, This characteristic is the reason square- oval passes are applied in several positions of a rod rolling sequence, even among the intermediate p: Although no quantitative border exists in this feature (since it depends on the groove radius), experts generally support an empirical line of hz/h)>0.6. This empirical border 0.6 is more relaxed than that of a box pass, 0.7, because of the more uniform distribution of the strain. Figure 6.10 shows the range of 2R/h, and hz/h; that satisfies the conditions discussed in this section. This figure suggests; + 2R/hy must be larger than 7.2 in a square-oval case, or larger than 4./ in a box-oval case + hz/hy must be larger than 0.6. + Larger h/t; requires larger rolls due to the A criterion. 4-05 7 (Square-Oval) A=0.75 (Box-Oval) 20.00 18.00 16.00 14.00 12.00 2R/h1 10.00 ac bite-angle=24° 0.90 0.55 0.60 0.65 0.70 0.75 0.80 0.85 h2/h1 Figure 6.10: Acceptable Range of the Roll Diameter and Reduction (Square-Oval)94 Examination of Parameter 25/w, Although Figure 6.5 suggests that this parameter should be larger, too large 2r/w; makes the oval groove shallow and flat, thus the product will be close to a rectangular aspect. That will make the deformation in the following square or oval pass complex, and will cause uneven strain distribution. Considered with the discussion in Section 6.4.1, the design procedure of parameter 2r/w; should include the following two ide: (3) The filling ratio should be smaller than 60% with respect to the robustness in spread. That is, larger 2r/w; is preferable. (2) However, smaller 2r/v; is preferable with respect to the uniform deformation in the following square or round pass. Thus, one should design 2r/v; so that the filling ratio will be 60%. 6.5 Robust Design Guidelines 6.5.1_Parameter w/hy Usually, this parameter is the result of the previous pass, or the material to be rolled. Any value of this parameter is acceptable since it does not have a significant effect on robustness. However, one needs to accurately grasp this value as the process background of the following design procedure. 6.5.2__Parameter 2R/hy ‘The flexibility of this parameter may be limited, since the decision process of the roll diameter may depend more on facility cost and process flexibility than on robustness in product geometry. The guideline discussed in this chapter is;95 2Rh; > 4.1 (Square-Oval) (6-8a) or 2R/h; > 7.2 (Box-Oval) (6-8b) Keeping this inequality, one should try to select the value of this parameter as close to the nominal value 10.0 as possible. In ideal, Figure 6.5 suggests the best recommended value as; 2Rf) = 10.0 (6-9) 6.5.3 Parameter ho/hy Once 2R/h; is decided, the next step should be the decision process of hy/h. Since this parameter is important for robustness (the larger the better), it should satisfy the A value and surface quality criteria keeping hz/h, value as large as possible. The discussion in Section 6.4.3 shows that h/h; must satisfy the following two inequality; Amhy{R(hy- hz)J95 < 0.5 (Square-Oval) (6-10a) of Axhy/[R(hy- hz)}5 < 0.75 (Box-Oval) (6-10b) yh; > 0.6 (611) 6.5.4 Parameter 2r/wy This parameter is also important for robustness in lateral spread. Section 6.4.4 developed a robust design guideline; gFr = 60(%) (6-12) where gFr is the filling ratio against the geometric width of the groove. Combined with hy/h}, This simple guideline leads to an appropriate value of 2r/Av; using the following logic. (1) Estimation of w/w, Equation 6-2 can estimate the after-rolling width w/w. This equation contains only 2R/h, and hz/hy as its independent variable.96 (2) Calculation of we/w; ‘The guideline for w., the geometric width of groove, is; Wg =W2/0.60 (6-13) (3) Caleulation of 2r/w; Based on the geometric relations, 2r/w; can be obtained by following equation; i Int — (614) rh, —f 7 ee 4 or (6-15) or 16) here, w2 can be calculated by another form of Equation 6-2 as following; w= (140.2 + 0.628*2R/hy - 47.5*hz/h)) x ws / 100 (6-17) Example of the Design Procedure The following procedure is an example of an oval roll pass design. It is assumed that this oval pass follows the box pass designed in Chapter V as the design example, (A) wj/hy is 1.54 as the result of the previous box pass. (2) 2R/hy has been selected as 10.0 for the ideal design for robustness. (3) hy/hy should be the largest value which satisfies the inequalities 6-10b and 6-11 to get the most robust design within the limitations. In this case, since w#/h, is quite large, A < 0.75 is applied. Then, 2R/hj=10.0 makes hy/h;=0.78. (4) w2/wzcan be estimated as 1.094 from Equation 6-17. (Then, ws/w; should be 1.823.)97 (5) 2r/w is calculated by Equation 6-16 as; 21 (yp gg4y2 154 1 ee w, O72 0.782 1.54 (6-18) This solution 2r/w; =3.5 will provide reasonable sobustness according to Figure 6.5. Table 6.9 shows preferred design parameters and an example design of a square-oval pass. Substitution of these design parameters for Equations 6-2 and 6-3 will provide the following information; (1) The percentage spread S, is expected to be 9.4%. That is, the stock with the width of 4.3” is expected to have the after-rolling width of 5.0". (2) The reduction of area Ar is expected to be 23.1%. This reduction seems an appropriate ratio for a square-to-oval pass. If these values are not preferable in some reason, one should reconsider the parameter hhy/hi, then cepeat the same design procedure. Table 6.9: Preferable Parameters and Example of Design (Square-Oval) Parameter Preferable Value Example of Design wy/hy - 17=2.8" (w/hy=1.54) 2R/hy 10.0 =14" hyfhy 0.78 hy=2.2" 2r/w} 3.5 r=7.5"98 6.6 Summary of Square-to-Oval Roll Pass Design Four parameters; w/hy, 2R/hy, h2/h}, and 2r/w; were defined as the design ‘parameters for square-oval pass design. The five noise parameters; A(w /hy), AR, Ahz, m, and AT represent all the process noise factors for a box pass. The tolerance analysis with SIN ratio shows clear trends that hg/hy and 2r/v; control the variance of Sp. As an interpretation of these trends for robustness, the more direct parameter groove filling ratio clearly showed the robustness trends and played an important role as a robustness criterion, On the basis of this criterion combined with practical restrictions, a robust design guideline for a square-to-oval pass was developed, ‘As a conclusion, the robust design guidelines for a square-to-oval pass are as follows: (1) w//h; and 2R/h; : The determination of these parameters often depends on other restricting factors, w/t; has very little effect on robustness, while the preferable value of 2R/h; is; 2R/hy > 4.1. (Square-Oval) (6-19a) or 2R/hy > 7.2 (Box-Oval) (6-19b) (2) hz/hy : From the viewpoints of side-wrinkling and double-bulge, this parameter bas 10 satisfy the following two inequalities: A=hy/[R(hj- hz)95 < 0.5 (Square-Oval) (6-20a) or A=hy/[R(hy- h2)]°> < 0.75 (Box-Oval) (6-20b) hyfhy > 0.6 (6-21) (3) 2r/w; : The following equation calculates 2r/v; to provide robustness in lateral spread: 6-22)99 ‘where w? is the width of the stock after rolling calculated by the following equation; wz = (140.2 + 0.628*2R/hy - 47.S*ho/h)) x w; / 100 (6-23) ‘The study in Chapter V and VI suggest that Taguchi method is quite functional and comprehensive, yet the output can not always be a direct conclusion. The important procedure in practical use of Taguchi method includes the interpretation of the output data,CHAPTER VII EVALUATION OF THE NEW DESIGN ‘This chapter evaluates the robustness of a square-box-oval sequence which includes the box and oval passes designed in Chapters ¥ and VI, comparing with an original sequence which used to be in practical use. 7.1 Parameters for Evaluation Design Parameters Table 7.1 contains the roll pass geometries involved in square-box-oval sequences of a original case and the newly developed case. The values of w; and h; for the oval passes (pass No2s) ate based on Equation 5-3 developed by regression analysis in Chapter V. Billet Pass#1 (Box) Pass#2 (Oval) Figure 7.1: The Square-Box-Oval Sequence 100101 Table 7.1: Design Parameters of Box and Square Passes in O1 jal and New Design Original Design New Design Pass#l (Box) wi/hy 1.0 1.0 2R/hy 4.0 3.5 hofhy 0.78 0.70 ww) 0.9 1.0 2rhv 0.65 0.7 a 40° 30° Pass#2 (Oval) wj/hy 14 1.5 2R/hy 5.2 10.0 hiofh 0.72 0.78 2rdv, 2.4 3.5 Table 7.2: Levels of Uncontrollable Factors (Evaluation Experiments) (a) Pass#1 (Box) Eactor Nominal Applied Levels Low High (dA) Awi/t,) 0 = 4.0% + 4.0% (dB) AR 0 7.0% + 7.0% (dC) Ah, 0 = 2.5% + 25% (b) Pass#2 (Oval) Factor Nominal Applied Levels Low High (dA) A(w;/h,) 0 (depends on previous pass) (dB) AR 0 - 7.0% + 7.0% (dC) hy 0 - 3.0% + 3.0% (m) om 0 0.5 1.0 ise Parameters The values of noise parameters are based on the discussion in Chapters V and VI. Tables 7.2 and 7.3 show the ranges of the noise parameters and the corresponding orthogonal arrays, respectively. Here, in the oval pass, the noise factor twist angle (AT) has been neglected because the incoming stock has a wide rectangular cross-section102 (v/h,>1.4). In addition, the oval pass applies the results of the previous box pass for the range of noise parameter A(w4/h;). The computer code TASKS executed these twenty-four (4x2+8x2) simulations. Table 7.3: Orthogonal Arrays for Uncontrollable Factors (Evaluation) (a) Pass#1 (Box) Runf dA dB dC 1 L L L 2 L H H 3 H L H 4 oH HL LiLow H:High (b) Pass#2 (Oval) Runf dA dB dC m 1 ob Lo Lo 2 bc t oc oH 30 F H H L 4c H H # 5 oH L H o-L 6 H L H H 7 H Ho LL 8 HH HL AH L:LowH: High 125.00 Initial Billet Width = 100% xm > 120.00 max zg ig 35-00 new design min S110. + 105.00 8 original & 100.00 design 95.00 Billet Box oval Pass Maximum and Minimum of Stock Width in Each Pass103 7.2 Results of the Evaluation (Data in Appendix-B) Figure 7.2 shows the plots of the direct measurements of maximum and minimum stock width in each pass. One can observe that the variance in stock width from the robust. oval pass is improved approximately into half of the original one. The standard deviation in each pass also show an improved value as observed in Figure 7.3. Figures 7.4 (a) and (b) show the edge filling ratio and groove filling ratio, respectively, compared between the original and new sequences. In the new sequence, the filling-ratio values are around 20% (box) and 60% (oval) as expected, while they are larger in the original sequence. The improvement in the box pass alone is not remarkable. 4.00. pital Billet Width = 100% 3.50 3.17 3.00 2.50 F199, 2.00 1.50 1.00 0.50 0.00 D original mnow 2.35 92 Standard Deviation (%) Box oval Pass Figure 7.3: Standard Deviation in Stock Width after Each Pass 30.0 80.0 max@ (a) ‘max @) z260 gi? nas 2420 fF mean Fr0.0 22.0 . a © 20.0 [mind |g 5.0 18.0 60.0 16:0 14.0 55.0 + orig. = orig. new Design Design Figure 7.4: Distribution of the Filling Ratios (a) Edge Filling Ratio in the Box Passes (b) Groove Filling Ratio in the Oval PassesFigure 7.; Profile of the Stock in Original Design Pass (a) Box Pass (Run#4) (b) Oval Pass (Run#7)105 Figure 7.6: Profile of the Stock in New Design Pass (a) Box Pass (Run#4)_(b) Oval Pass (Run#7)106 Figures 7.5 and 7.6 show the profiles of the rolled stocks in the original and new passes, respectively. Each figure shows the result of the simulation in which the largest spread (or absolute width) was observed. 7.3 Discussion 7.3.1_Variance in Stock Width Figure 7.2 suggests that the original sequence enlarges the deviation in width during the rolling process, while the original sequence keeps the deviation almost constant. The groove filling ratio at the original oval pass is 73%, while 60% at the new oval pass. At the original oval pass, the large filling ratio leads to large variance in the lateral width. Following is the verification of each design parameter in the original oval pass on the basis of the tolerance analysis discussed in Chapter VI. (1) wi/hy : The mean of this value is /.4 in the original case. Since Figure 6.5 suggests that this parameter does not play an important role for robustness, this value should be acceptable. (2) 2R/h, : The mean of this value is 5.2 in the original case. Figure 6.5 suggests that smaller value than 10.0 should lead to robustness. However, this value does not satisfy Equation 6-8; the following section will discuss this matter. (3) ha/hy : The mean of this value is 0.72 in the original case, while 0.78 in the new design. Since larger value of this parameter significantly leads to robustness, the new design should show the smaller variance than the original one in respect of the parameter hafhy.107 (4) 2r/w, : The mean of this value is 2.4 in the original case, while 3.5 in the new design, Since larger value of this parameter significantly leads to robustness, the new design should show the smaller variance than the original one also in respect of the parameter 2r/v;. The discussion above suggests that the original oval design contains smaller values in hyfh and 2rhv}, which will lead to large variance in the lateral spread or stock width. To partially improve this problem, one may be able to take a measure almost instantly by reducing the value of hy, ic., reducing the groove height (or roll gap) of the previous box pass. Increasing the value of hg is not preferable because that may lead to more dangerous range in A-value. However, the former measure may include a problem in increased roll separating force. One can observe that Figure 7.5, the rolled profiles in the original sequence, have slightly double-bulged profiles, while Figure 7.6 does not. These profiles suggest that the roll radii applied to the original sequence may be too small, and/or the values of the design parameter hi2/h, may be too large, according to the recommended conditions given by the inequalities 5-10 and 6-10. That is, the original sequence might deform only the surface layer of the billets, even if a double-bulge did not occur in an actual rolling process because of the heat transfer between the rolls and the stock (ie., the simulation by TASKS assumes isothermal situations in this research).108 7.4 Conclusions (1) The new square-box-oval sequence designed on the robustness guidelines expectedly indicated a reduced variance in the stock width at the oval pass. The robust design of the oval pass contributed the most part of the improvement. The design modification of the original square-box-oval sequence into the newly developed one reduced the variance in the stock width as much as 50%, (2) In the original sequence, the roll radius in the oval pass was so small that a double- bulge or non-uniform deformation might take place. Coupled with the effect in reducing the lateral variance, the evaluation experiments can conclude that the original sequence considerably contains the necessity of modification into the newly developed design.CHAPTER VIII A BRIEF INTRODUCTION TO ROBROLL This research has developed the guidelines for robust design of a square-box pass and a square-oval pass. The developed concepts include systematic procedure, yet the application to the actual design work may require some complex calculation steps. This chapter introduces a software system ROBROLL (ROBust Design of ROd RoLLing Pass) that organizes the robust design guidelines developed in this study. The software programs are developed on the properties of HyperCard, Apple Computer. 8.1 Objective of Development There are several processes required to reach the optimized design advocated by this study. Since complex criteria support the process logie, it may be troublesome to look into the background information every time one tries to apply the design guidelines. The primary objective of this software development is to totally organize the achievement of this study. The objective includes the goals for the practical usage listed below: i09110 (1) To easily apply the achievement of this study to the practical roll pass design process, (2) To comprehensibly provide the calculation procedure and background data for the users. 8.2. Design Feature of the System (1) Preparation of Guidance System: Because of the complexity of the background information, several stages of guidance cards are necessary for each step of the design procedure. However, they must not bother those users who have already gone through this system. Consequently, this system can not consist of only one stream of procedure; it needs some branch display cards that are to be optionally shown to the user. (2) Mapping and Visual Feedback: Because of the complex structure of this system, it needs always to show the procedure steps to the user. The small "map" of the system (a reduced copy of Figure 8.1) always tells the user where he/she is now. 8.3 Basic Function of the System M: job Flow The basic job flow of this system is as follows: (1) Roll Pattern Selection : The user selects the roll pattern, square-to-box or square- to-oval. Each pattern has its own job cards separated from each other.ul (2) Background Parameter Input : The user must give material geometry and roll radius as the background data to the system. Usually these parameters have very little flexibility in their design. They may have other restricting factors such as equipment size, facility spaces, billet rolling process restriction, and so on, However, in the Evaluation step (mentioned later), the system evaluates also these background parameters to suggest the viewpoints of improvement, (3) Design Parameter Input : The user gives the groove design parameters to the system, In this step, the user can select one of the two process options: * The user can put his/her own or existing design parameters. + The system can calculate the optimum parameters based on the background data. The optimization criteria for the automatic system calculation are the same as ones used for the evaluation process. That is, the automatic design function may play a role of “instant design." (4) Evaluation : This process evaluates the design, including the background parameters, using several criteria developed in Chapter V and VI of this thesis. The system gives the design a grade of 100 scale, accompanied by short comments for the total design and each parameter. (5) Suggestion for Improvement: The user can get some information in the reason of the grade. Then the user may get to know how he/she should redesign the parameters. 8.3.2 Benchmark Tasks Each process of the design procedure may include several cases of combinations in known and unknown information. Table 8.1 shows the benchmark tasks to reach the best design.112 Table 8.1: Benchmark Tasks of the System 1. Background Knowledge 1-a, Basic Knowledge Rod Rolling Process 1-a-1, User is a roll pass designer (Expert) 1-a-2, User has basic knowledge (Engineer) 1-a-3. User has a little knowledge (Beginner-engineer) 2. Design / Setting of Roll Pass Geometry 2-a. Pattern Selection ‘2-al. User is going to design a box pass User is going to design an oval pass 2-b, Definition of Material Geometry 2-b-1. Material geometry known 2-b-2. Material geometry unknown 2-b-2-1. User knows restriction of material geometry 2-b-2-2. User doesn’t know restriction of material geometry 2-c. Definition of Roll Pass Geometry 2-1. Already designed 2-¢-2. Design now 2-c-2-1. User can estimate roll pass geometry 2-¢-2-2. User can estimate roll pass geometry with a little guidance 2-c-2-2. User can't estimate roll pass geometry at all 3. Evaluation 3-a, Result of evaluation 3-2-1. Result of evaluation is “excellent” 3-a-2. Result of evaluation is not “excellent” Za-l-I. User figures out why not excellent 3-a-1-2. User doesn’t figure out why not excellent Focus of improvement 3-b-1. User doesn’t need explanation 3-b-2. User needs explanation 4, Improvement 4-a, Improvement not necessary 4-b. Improvement and re-evaluation necessary 8. tructure (1) Main stream cards follow the basic design procedure. These card screens include: + Pass pattem selection + Background data input + Design parameter input / Automatic design option + Evaluation113 (2) Branch cards provide background information for the users to grasp what the system is trying to do and how the system works. These cards include: + Explanation of each step of this system + Guidance for parameter input + Suggestion for design improvement and others. Figure 8.1 below shows the structure of Main Stream in this system. Square-Box| [ Squre-Oval — Background Input Parameter Input| | Automatic Design —_ Evaluation Suggestion for Improvement Figure 8.1: Structure of the Main Stream in ROBROLLCHAPTER IX SUMMARY AND FUTURE DIRECTION 9.1 Summary This research investigates the application of robust design techniques to the roll pass design of a square-to-box pass and a square(box)-to-oval pass for hot rolling process of steel rods, The goal of this research is to achieve a minimum variance of lateral spread in the rolled stock under the process noise factors. Spread during hot rolling of rods is determined by simulations on the FEM code TASKS. These simulations are combined with the Taguchi method for tolerance analysis, which leads to general design guidelines of a square-box-oval sequence to reduce variance in fateral spread. This study achieved the following general ideas: (1) Combined with the FEM simulation technique, the tolerance analysis in the Taguchi method found the design parameters that significantly affect the variance in the lateral spread in a square-box and a square(box)-oval rolling passes. Arrangement of those parameters showed the direction for the optimum design of each pass. (2) Comparison with the common knowledge in rolling found the general robustness trends, then led to the optimum design of a square-box-oval rolling sequence. The 14us guidance parameters edge filling ratio and groove filling ratio are found to play important roles in the design optimization. (3) The new square-box-oval sequence designed on the robust design guidelines showed a reduced variance in the width of the final oval stock. The original design may have problems in its box pass and oval pass, with respect to the non-uniform deformation and robustness in lateral spread, respectively. Figures 5.9 and 6.5 provide the directions that lead to robustness for each design parameter. Besides these directions, the following formulae should manage the design parameters for robust design; Square-Box: (oR, Mb = 1.34- aond*! +-o.008e4 2) oan 2) - on tM ama (9-1) wr hy X hy J hy yw 21 I ? Square-Oval: SiMe) (9-2) w, 0.72 \w) hy The new square-box-oval sequence designed on the robust design guidelines developed in this research shows a reduced variance in the width of the final oval stock. The original design may have a problem in its oval pass. ‘The formulation of the robust design guidelines developed a HyperCard design guidance system called ROBROLL. In this study, the computer code TASKS executed the experiments. Hence, this study may only be as good as the accuracy of this software. However, past verification studies indicate that the program is quite accurate in simulating rolling processes (Kim et al., 1991, Lee et al., 1992). ‘The conclusions of this study are quite reasonable from a view of the author's ten-year experience in the field of rod rolling.116 9.2 Conclusions The design guidelines developed in this study provided a new roll pass design for a square-box-oval sequence to improve the variance in rolled profile. Compared with the original sequence design, the new design will improve the uniformity of deformation in the box pass as well as the variance in rolled profile. Table 9.1 shows the new parameters designed in this research. Table 9.1: Parameters in the New Design of the Square-Box-Oval Sequence ‘Square-Box Pass Box-Oval Pass wj/hy 1.0 1.5 (depends on box pass) 2R/hy 35 10.0 hiafhy 0.70 0.78 wyhvy 100 meee 2rhwy 0.7 3.5 a a 9.3 Application The design guidelines developed in this study would provide a quantitative support for the field of roll pass design. A design guidance system such as ROBROLL demonstrated in this research would play an important role as an information tool. If an existing rolling sequence had a problem in its design with respect to the robustness, application of the results in this study would also provide a considerable support for improvement of the variance in the rolling profile, which would lead to high quality in the products. Although the range of the parameters covered in this study should be wide17 enough to fit the most of the box and oval processes for steel rod rolling, one may need to be careful if some of the parameters are out of the covered range. This research has found that an oval pass has a dominant effect for geometric variance, thus one may mainly focus on oval passes in developing a new sequence or in modifying an existing sequence. Although this study discussed only a square(rectangle)- to-oval pattern, the ideas in the robustness trends and guidelines would be the same if the previous pass was a round or a slug (e.g., pass#4 in Figure 1.1). In addition, even though the noise factors discussed in this study may differ in actual rolling (e.g., existence of significant inter-stand tension instead of roll displacement in a finishing block mill), the basic ideas for robustness trends would be the same. 9.4 Future Direction ‘This study focused on the two typical patterns of rod rolling passes, square-to-box and square-to-oval. 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(1978) “Performance Analysis Design.” International Journal of Production Research, 16, pp.521-530. Taguchi, G. (1987) System of Experimental Design. Edited by Don Clausing, American Supplier Institute, Dearborn, MI. The United Steel Co., Ltd. (1960) Roll Pass Design. Percy Lund, Humphries & Company Ltd., London, U.K.122 Yoshimura, K., Shivpuri, R., and Ishii, K. (1995) “Robust Design of Square-to-Box Rolling of Steel Rods.” Submitted to the 1995 ASME Design Automation Conference. ‘Yu, J. and Ishii, K. (1994) “Robust Design by Matching the Design with Manufacturing igs of 1994 ASME Advances in Design Automation Variation Patterns” Procee Conference. September 1994,Appendix-A Data Tables of Screening Experiments 123,10 u 2 B 15 Table A.1: Height in.) 4.42 4.40 431 4.23 4.30 4.09 4.50 4.42 4.32 4.65 4.42 437 439 452 4.36 Table A.2: Height Gin.) 2.13 213 2.13 2.24 2.18 2.20 2.16 2.18 2.15 2.10 2.12 2.16 219 2.18 2.15 Background Data (Oval-Square Expe Billets Width Temp. (in) CO) 172 931 1.74 840 172911 168847 1.69 909 170 872 166 942 182 885 179 898 174 883 170 898 172 920 172 918 172 884 1.69 882 Icy (%) 0.77 0.80 0.10 0.10 0.62 0.72 0.48 0.80 0.80 0.62 0.80 0.75 0.7 072 080 (in) 8.53 8.53 8.53 8.79 8.79 8.79 8.79 8.79 8.79 8.79 8.79 8.79 8.00 8.00 8.00 ~ Rolls (rallsec) (on) 2.72 2024 195 2150 2.04 2276 2.09 36 210 414 2.06 710 2.35 1240 2.23 1444 2.28 1702, 1441860 2.46 1976 2.46 2442 2.29 26 189 146 152 950 Cin.) 257 2.59 2.56 2.56 2.53 2.54 251 2.67 2.64 2.59 255 257 257 2.57 2.55 Background Data (Square-Oval Experiments) Billets ‘Width Temp. fin) CO) 2.13 882 2.13 830 213 843 224 763 218 898 2.20 836 216 888 218 886 21S 928 210 878 212 915 2.10 903 219 851 218 829 21S 853 J Ic %) 0.77 0.80 020 0.10 0.62 0.72 0.48 0.80 0.80 0.62 0.80 0.75 0.77 0.72 0.80 Gin} 8.28 8.28 8.28 8.28 8.28 8.28 8.28 8.28 834 8.34 834 834 8.34 8.34 8.34 (rad/sec) 441 3.18 3.29 3.36 3.47 3.44 3.95 3.99 4.05 2.59 4.39 4.28 3.33 3.42 2.64 ~ Rolls ~- Radius Ang. Velocity Tonnage Groove Height (ion) 218 350 470 810 1240 1484 2014 2248 88 246 362 828 1006 1306 1810 in.) 1.26 1.25 125 121 1.16 116 1.13 Las 124 1.16 119 117 117 Li7 Lid RadiusAng.Velocity Tonnage Groove Height } 124125 Table A.3: Simulation Data Compared with Actual Measurements (Oval-Square Experiments) Ws: Width in Simulation Wa : Width in Actual Measurement Ts: Torque in Simulation Ta : Torque in Actual Measurement L ‘Temperature Adjusted ‘Temperature = 110°C -- ] No. WsWa ‘Ts/Ta m WsWa = TsTa m=0.5 9 m=1.0 m=0.5 — m=1.0 : Frictional Coefficient I 099 100 0.780.830.7501 0.56 2 093 099 LIL L975 1.00 0.65 3 093 097 = «0.78083 O75 0.98, O51 4 091 093 064 069 075 0.94 0.42 5 092 095 076 O81 075 0.96 0.50 6 089 093 076 080 075 0.93 0.42 7 093° 092 0.700.750.7591 0.49 8 092 097-087-093 0.75 0.98 057 9 096° = «10107808375 1.02, O51 10 090 097 0.69.74 0.75 0.98 0.45 u 089 = 0.94 0.78083 0.75 0.96 051 2 093° 100088) 0.94 = 0.51.01 0.58 3 095 0.93088 0.93075 0.94 0.55 14 095 0.94 0.80085 0750.95 049 15 090 094 «0.83 «088 0750.95 0.51 Table A.4: Simulation Data Compared with Actual Measurements (Square-Oval Experiments) Ws : Width in Simulation Wa : Width in Actual Measurement Ts: Torque in Simulation Ta : Torque in Actual Measurement _m: Frictional Coefficient t ‘Temperature Adjusted — ‘Temperature = 1100°C ~ No. WsWa ‘TsTa mm WsWa = TSTa m=05 m=1.0 1S m=1.0 1 087 091 085 O91 1.00 092 0.58 2 090 «094 105 112 1.00 095 0.70 3 092 095 «1051S 0.75 0.95 0.69 4 094 101 «1.191975, 099 ORT 3 093 «100 099 «137050092 O61 6 097 «105 1.1918 0.50 0970.67 7 096 = =1.04 = «1.04133 0.50 0.96 0.65. 8 098 105 «1.19 1.00 0.50 0.98 0.74 9 089 == 094 = 0930.91 1.00 0.94 0.68, 10 O85 091 081 074 1.00 092 0.53 ul 084 088 098 106 1.00 090 0.68, 2 091 094 693 101 075 093 0.62 13 091 «0971.00 1.1 0.75096 0.60 4 094 101 127° 14t. 050094 0.70 1s 093 «100 «130147, 0.50093 0.72Appendix-B Data Tables of Evaluation Experiments 126Table B.1: Initial Billets = 100h x 100w W2 : Stock Width after Rolling ~ Original Design RunNo. — W2 Sp 1 105.14 5.14 2 103.63 3.63, 3 106.18 6.18, 4 10837 8.37 mean 10583 5.83 s 1991.99 r 44 4.74 Sp: Percentage Spread ] er 23.12 20.83 24.72 28.07 24.19 3.04 7.24 106.39 106.13, 109,93, 110.67 108.28 2.35 454 Sp 639 6.13 9.93 10.67 8.28 2:35 4.54 New design Simulation Data in Bex-Pass Evaluation Fr 14.85 15.16 24.57 26.40 20.25 6.10 11.55 Table B.2: Simulation Data in Oval-Pass Evaluation Initial Billets = 100h x 100w Stock Width before Rolling (Results of the Run No.2 or 4 in previous box pass simulation) gFr : Groove Filling Ratio Wi W2: Stock Width after Rolling RunNo. WI eudanaun 103.63 103.63, 103.63 103.63 108,37 108.37 108.37 108.37 Sp: Percentage Spread Original Design W2 Sp 11343 7.18 11534 8.99 118391187 1241 5.93 11757 11.09 11882 1227 12207 15.35 11702 10.57 11684 10.41 3.17 3.00 9.96 Oat Fr 70.30 72.50 74.41 70.47 wi 106.13, 106.13, 106.13 106.13 110.67 110.67 110.67 110.67 New desig w2 SI 116.03 6.93 571 6.61 11788 8.62 115.40 6.33, 119.57 10.18 119.29 9.92 120.02 10.59 119.29 9.92 117.90 8.63 1921.77 462 4.25 127 Fr : Edge Filling Ratio gFr 59.12 58.96 60.07 58.80 60.93 60.79 61.16 60.79 60.08 0.98 2.35 Run No.1~4 follow the Run No.2 in the box pass evaluation (Table B-1) Run No Sp is calculated due to the mean width after the previous box pass ~8 follow the Run No.4 in the box pass evaluation (Table B-1)