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Article history: The main factors influencing on the level of residual stresses in hot rolled steel strips are
Received 4 August 2017 related with uneven temperature and microstructure changes during cooling on the run-out
Accepted 7 November 2017 table and in a coil. That is why in this work, development of coil cooling model with taking
Available online 16 December 2017 into account the influence of radial stresses on the effective thermal conductivity in the
radial direction was performed. In order to assess the influence of the phase transformations
Keywords: in the coil on the level of residual stresses, the different laminar cooling strategies were
Residual stress applied. The results of numerical simulations obtained in this work were validated in
Hot-rolled steel coil industrial conditions. It is shown that the end of phase transformations in the strip coil
Radial thermal conductivity has a significant influence on the level of residual stresses.
Phase transformation © 2017 Published by Elsevier Sp. z o.o. on behalf of Politechnika Wrocławska.
* Corresponding author.
E-mail address: switek@agh.edu.pl (S. Witek).
https://doi.org/10.1016/j.acme.2017.11.002
1644-9665/© 2017 Published by Elsevier Sp. z o.o. on behalf of Politechnika Wrocławska.
660 archives of civil and mechanical engineering 18 (2018) 659–668
ing and cooling [3], and phase transformation occurring during Hence the objectives of the current work are twofold. The
cooling [4]. first objective is to develop and experimental validation of the
In the last two decades, several studies have been made for coil cooling model with taking into account the key parameters
computing of residual stresses in hot-rolled steel strip for influencing on the radial thermal conductivity of the coil
enhancing the final product quality [4–8]. Zhou et al. [4] during cooling. This model is crucial to thoroughly investigate
performed a preliminary computational study of residual the effect of phase transformation in the coil on the level of
stresses developed during cooling on the ROT using ABAQUS residual stresses, which states the second objective of the
software. The investigations were continued and results have current work.
been published in [5]. It was concluded that the temperature
profile along the strip has little effect on residual stresses but
transverse temperature gradient plays a pivotal role. In work
[6], a three-dimensional FE model was established and later 2. Numerical models
improved [7] to analyze the residual stresses developed during
the cooling of hot rolled strip on the ROT. This model was also 2.1. Rods model of residual stresses
performed using ABAQUS software. The results showed that
temperature drop within the strip edge region resulted to the A model to predict the residual stresses formation in hot-rolled
development of edge waviness. To better control the flatness strips during laminar cooling, coiling and cooling in the coil
quality of steel strip, the strip shape compensation control was presented in the article [9]. The mechanical part of that
strategy of slight center wave rolling and edge masking were model was based on the assumption that all components of
proposed. Cho et al. [8] developed a three-dimensional the stress tensor except tension along the length of the strip
numerical model to predict the edge wave behavior of hot are zero. Verification of this assumption was performed by an
rolled steel during ROT cooling based on FEM. The effect of the experimental study of residual stresses in strips rolled in
edge mask width and the checkers on the edge wave were industrial conditions. It was shown that only longitudinal
examined through a series of process simulations. stresses have significant influence in the rolling process. That
In general, it was proved that the optimization of the is why, in this model the profile of strip was presented as a
cooling process allows to reduce the level of residual stresses system of rods interconnected at the ends. In addition to the
to avoid strip flatness defects. However, the long computa- thermal deformation of each rod, all the rods were exposed to
tional time of these models does not allow to use them in the the average strain of the strip em that is a result of the changing
control system of the rolling mill. To solve this problem, the of the length of the strip in the cooling process. Thus, if in the
model of residual stresses based on fast computing methods rod i an increment of temperature Dt and the corresponding
was developed [3,9,10]. The proposed model was composed of increment of thermal deformation Det appeared, the total
mechanical and thermal parts that enable the modeling of increment of the deformation Dei of the rod is equal to:
thermo-mechanical and microstructural phenomena for the
entire manufacturing process of strip.
Dei ¼ Dem Det jc DtDeb (1)
A significant influence on the residual stresses is provided
by cooling in a coil. This is due to the fact that cooling in the where Dt is an increment of time; jc is the rate of creep; Deb is an
strip coil is most unevenly along the length and width of the increment of deformation during coiling and uncoiling pro-
strip. This especially affects the residual stresses in the case cesses. The current strain of the rod i is:
when the phase transformation does not have a time to
complete at the laminar cooling stage on the ROT. In this case,
there are two factors that increase the magnitude and uneven X
J
ei ¼ Deij (2)
distribution of residual stresses. The first is associated with the j¼1
generation of heat during the phase transformations in the
where J is the number of increments of time, j is the current
coil. This can lead to uneven heating of the coil during the
number of step.
initial cooling stage. The second factor is related to the
dilatation of the material during the phase transformations, The increment of the thermal deformation was determined
which directly affects the magnitude of the stresses. Thus, in taking into account phase transformations. This relation can
the described situation, the accuracy of the temperature model be represented in a general form:
of the cooling process in the coil must be higher than is usually
considered sufficient. In particular, the anisotropy of the
thermal conductivity caused by the loose contact of the turns Det ¼ f t; tÇ; Dt (3)
and the features of the strip surface must be taken into
where tÇis the cooling rate, t is the temperature.
account. This question in the existing works is usually solved
in a simplified manner [9]. Thermal conductivity in the radial Increment of deformation during coiling and uncoiling
direction is adopted as a part (usually in the range 0.05–0.2) of processes can be calculated from the equation, which was
the thermal conductivity of the base material. In the presence obtained from geometrical interpretation of bending:
of phase transformations during cooling in a coil, this
approximation is insufficient, since the sensitivity of residual
y
stresses to temperature increases. Deb ¼ (4)
2Rcoil
archives of civil and mechanical engineering 18 (2018) 659–668 661
where Rcoil is the radius of the curvature of the strip at the where c(t) is the specific heat, r(t) is the density, t is the time, kr,
coiling, y is the coordinate of the rod relative to the neutral line kz is the thermal conductivity in radial and axial directions
of the bend. The value y changes according to the plate thick- respectively, qtrans is the latent heat of phase transformations, t
ness h in the range of ½h=2; h=2. is the temperature.
Increment of stress in rods can be defined in general form The generation of heat due to phase transformations are
as elastic–plastic model of one rod, which takes into account calculated by the following equations:
loading and unloading processes:
f dFf p dFp dF
qtrans ¼ r Htrans þ Htrans þ Hbtrans b (9)
Ds i ¼ Ds i ðt; ei ; Dei ; Dem Þ (5) dt dt dt
f p
where Htrans , Htrans , Hbtrans is an enthalpy of the phase transfor-
In the considered method Dem is an unknown quantity. mations; Ff, Fp, Fb is the volume fractions of ferrite, pearlite and
Determination of Dem was carried out on the basis of the bainite with respect to the whole volume of the material.
conditions of equilibrium of the system of k rods:
f p
The parameters Htrans , Htrans , Hbtrans , c(t) and k are adopted
X
k
according to Medina [11] for the steel A36. The convection
Ds i ðt; ei ; Dei ; Dem ÞSi ¼ 0 (6)
i¼1
boundary condition is applied according to equation:
2.2. Phase transformations model The heat transfer coefficient was determined for the
conditions of natural air cooling (convection and radiation)
The phase transformations model used in the current work from the oxidized surface of steel strip [12]:
was thoroughly presented in [9]. This model is based on
modified JMAK equation. The basic form of this equation is:
a ¼ exp 3:285 þ 1:57103 t (11)
X ¼ 1expðktn Þ (7)
2.3.1. Effective radial thermal conductivity
where X is the volume fraction of a new phase, t is the time, k, n A solution of Eq. (8) requires knowledge of thermal conductiv-
is the coefficients. ity along both the radial and axial directions of the coil. Due to
the anisotropic structure of the coil which is composed of
Model consists the coefficient k which is defined as a many steel layers and air gaps between them, the thermal
temperature function k = f(t). Coefficient k should map the conductivity in the radial direction is quite different from in
form of a TTT diagram. Various function of k are used for axial direction. In this case the thermal conductivity along the
ferritic, pearlitic and bainitic transformations. Theoretical axial direction is equal to conductivity of the strip material
considerations showed that, according to transformation type [13]. Due to the various mechanism occurring during cooling,
(nucleation and growth process, site saturation process) a the effective radial thermal conductivity (ERTC) are not only
constant value of coefficient n in Eq. (7) can be used. For more function of the thermal conductivity of the base material. In
details, see [9]. general, the ERTC of the coil depends on some factors
interacting with each other [14]:
2.3. FEM models of thermal processes
material properties,
The processes occurring in the strip after the coiling process temperature,
are started at the laminar cooling stage and rolling process. surface characteristics of strip,
Therefore the developed FE thermal model is divided into two the compressive stresses in the radial direction,
parts. The first is modeling of the heat transfer in the strip strip and interface thickness.
during rolling and laminar cooling. This model is based on the
two dimensional Fourier equation for the cross section of the In order to determine the effective radial thermal conduc-
hot-rolled strip with taking into account the heat of deforma- tivity, the coil can be modeled by using a concept of
tion and latent heat of phase transformations. The second part representative unit layer and the thermal resistance analysis
of the thermal model is designed for modeling of cooling in the [13–15]. In this case, the ERTC at a specified temperature and
coil. That model is based on the solution of Fourier equation in location of the coil is equal to the conductivity of the modeled
the cylindrical coordinate system: unit layer. Schematic diagram of representative unit layer is
shown in Fig. 1.
2 Considering the total thermal resistance and thickness of
dt @ t 1 @t @2 t the unit layer, the effective thermal conductivity, kr, can be
cðtÞrðtÞ ¼ kr þ þ kz 2 þ qtrans (8)
dt @r2 r @r @z given as follows:
662 archives of civil and mechanical engineering 18 (2018) 659–668
bs þ 2bo þ bi
kr ¼ n 1 o (17)
bs =ks þ 2bo =ko þ ð1:13A0:94 ks m=s p Þ þ ðð1AÞka =bi Þ þ 4ð1AÞeSt3
archives of civil and mechanical engineering 18 (2018) 659–668 663
Fig. 2 – The relationship between the ERTC and compressive stresses computed for 4 mm strip thickness (a), and CFTC
variations under compressive stresses computed for 2 mm and 4 mm strip thickness (b).
Fig. 3 – Temperature variations at points P1 and P2 calculated using constant CFTC and stress dependent EFTC.
2 mm and 4 mm strip thickness is presented in Fig. 2b. It is real production process and conditions in the hot strip mill in
clear that the coil with greater strip thickness has higher CFTC. ArcelorMittal Poland. Low carbon steel S235 with the chemical
compositions given in Table 1 was selected as the main
investigated material. Experimental rolling of the steel S235
3. Verification of model and analyses of
were carried out. The process of the rolling of 4 mm thick steel
sensitivity
strip from a slab measuring 220 mm 1529 mm 11,034 mm
in 11 stands has been performed. The first five of the stands are
Figs. 3 and 4 show the numerical results of temperature a roughing train and the remaining stands form a finishing
distribution (for selected points P1 and P2) and residual train. Schedule of deformation during hot rolling is shown in
stresses obtained for two variants of simulation for steel Table 2. In the rolling experiments, two variants of cooling
S235. In the first case, the influence of radial thermal stresses conditions were applied. The schematic representation of
on the radial thermal conductivity is taken into account. In the applied laminar cooling strategies, namely, early and late
second variant, the radial thermal conductivity is obtained by
multiplying the thermal conductivity of material strip by
constant correction factor equal 0.2. The obtained results
presented in Figs. 3 and 4 allow to conclude that including in
the calculation the influence of radial thermal stresses on the
ERTC has a huge impact on the temperature evolution of the
strip coil, and, consequently, substantially changes the level of
residual stresses.
Validation of the developed model of coil cooling and complex Fig. 4 – Residual stresses in strip for steel S235 calculated
model of residual stresses was conducted on the basis of the using constant CFTC and stress dependent EFTC.
664 archives of civil and mechanical engineering 18 (2018) 659–668
cooling mode is shown in Fig. 5. In the experiment, the were cut from the outer wrap of the coil. Figs. 8 and 9 show that
temperature measurement of the coils were made using the calculation results of residual stresses are in reasonable
portable infrared camera FLIR SC660 which was placed in front agreement with the experimental data in both cases. However,
of the coil. The emissivity coefficient for investigated steel was some discrepancies between measurements and predictions
0.85. The temperature of the coils was measured after are observed probably due to additional uneven deformation
removing the mandrel. The temperature distributions com- caused by the roller leveler in the leveling process of the strip.
parison between the actual measurement and the calculation
is shown in Figs. 6 and 7. As it is seen in this Figs., in both cases,
5. Results of modeling and discussion
the computed results are close and showed good agreement
with the experimental data. The measurements of residual
stresses in strips have been performed by X-ray diffraction Numerical simulations of residual stresses arising in laminar
method and are described in work [17]. The samples of sheet cooling, coiling and cooling in the coil were performed for low
Fig. 6 – Calculated (a) and measured (b) results of temperature distribution in the coil for early cooling mode.
archives of civil and mechanical engineering 18 (2018) 659–668 665
Fig. 7 – Calculated (a) and measured (b) results of temperature distribution in the coil for late cooling mode.
Fig. 8 – Calculated and measured results of residual stresses in strip for early cooling mode.
carbon steels S235 and S355. The chemical compositions of study the influence of laminar cooling conditions on the
both steels are presented in Table 1. It is worth to emphasize, evolution of phase transformations, as well as on the level of
that investigated steels S235 and S355 are characterized by residual stresses, two variants of the simulation for every each
different carbon and manganese content. Thus, the significant steel were performed. These two variants are differed from
differences in the evolution of phase transformations and final each other by applied cooling mode. The simulation condi-
volume fractions of each phase can be expected. In order to tions such as rolling schedule or cooling strategies were the
Fig. 9 – Calculated and measured results of residual stresses in strip for late cooling mode.
666 archives of civil and mechanical engineering 18 (2018) 659–668
Fig. 11 – Distribution of bainite (Fb) and pearlite (Fp) in the coil after cooling processes and in measurement points (P1, P2)
during cooling for steel S235 for early (a) and late (b) cooling mode. LCL – laminar cooling, CCL – cooling during coiling and in
the coil.
archives of civil and mechanical engineering 18 (2018) 659–668 667
Fig. 12 – Distribution of bainite (Fb) and perlite (Fp) in the coil after cooling processes and in measurement points (P1, P2) during
cooling process for steel S355 for early (a) and late (b) cooling mode.
Fig. 13 – Calculation results of residual stresses for steel S235 for early and late cooling mode.
Fig. 14 – Calculation results of residual stresses for steel S355 for early and late cooling mode.
668 archives of civil and mechanical engineering 18 (2018) 659–668
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