Flat rolling is considered to be one of the most important and most widely used metal forming processes. This book emphasizes the importance of mathematical simulation of this process in the light of the ever in- creasing need for quality improvements through automation. Mathematical models of the hot, warm and cold rolling processes are discussed, compared and critically evaluated. Engineers in the steel industry will find this book particularly useful in their everyday work.
Flat rolling is considered to be one of the most important and most widely used metal forming processes. This book emphasizes the importance of mathematical simulation of this process in the light of the ever in- creasing need for quality improvements through automation. Mathematical models of the hot, warm and cold rolling processes are discussed, compared and critically evaluated. Engineers in the steel industry will find this book particularly useful in their everyday work.
Primer on Flat Rolling is a fully revised second edition, and the outcome of over three decades of involvement with the rolling process. It is based on the author's yearly set of lectures, delivered to engineers and technologists working in the rolling metal industry. The essential and basic ideas involved in designing and analysis of the rolling process are presented. The book discusses and illustrates in detail the three components of flat rolling: the mill, the rolled metal, and their interface. New processes are also covered; flexible rolling and accumulative roll-bonding. The last chapter contains problems, with solutions that illustrate the complexities of flat rolling. New chapters include a study of hot rolling of aluminum, contributed by Prof. M. Wells; advanced applications of the finite element method, by Dr. Yuli Liu and by Dr. G. Krallics; roll design by Dr. J. B. Tiley and the history of the development of hot rolling mills, written by Mr. D. R. Adair and E. B. Intong. Engineers, technologists and students can all use this book to aid their planning and analysis of flat rolling processes. - Provides clear descriptions for engineers and technologists working in steel mills - Evaluates the predictive capabilities of mathematical models - Assignments and their solutions are included within the text
The objective of this publication is to comprehensively discuss the possibilities of producing steels with pre-determined attributes, demanded by the customer to fit exacting specifications. The information presented in the book has been designed to indicate the reasons for the expenses and to aid in the process of overcoming the difficulties and reducing the costs. In nine detailed chapters, the authors cover topics including: • steel as a major contributor to the economic wealth of a country in terms of its capabilities and production • current concerns of major steel producers • phenomena contributing to the quality of the product • information concerning the boundary conditions of the rolling process and initial conditions, put to use by mathematical models • the solid state incremental approach and flow formulation • parameters and variables - most of which make use of the exponential nature of phenomena that are activated by thermal energy • the application of three dimensional analysis to shape rolling • the evaluation of parameters by a form of inverse analysis to the flat rolling process • knowledge based modeling, using artificial intelligence, expert systems and neural networks They conclude that when either mathematical or physical modeling of the rolling process is considered and the aim is to satisfy the demands for customers, it is possible to produce what the customer wants, exactly.
The result of a fruitful, on-going collaboration between academia and industry, this book reviews recent advances in research on oxide scale behavior in high-temperature forming processes. Presenting novel, previously neglected approaches, the authors emphasize the pivotal role of reproducible experiments to elucidate the oxide scale properties and develop quantitative models with predictive accuracy. Each chapter consists of a detailed, systematic examination of different aspects of oxide scale formation with immediate impact for researchers and developers in industry. The clear and stringent style of presentation makes this monograph both coherent and easily readable.
This book offers a unique approach to integrated high-temperature process modelling, intended to serve as a design aid for new metal processing technologies. The second edition has been substantially expanded to include new content such as: a new algorithm and test results of 3D stereoscopic visualization; new programming procedures for modelling; the validation of computer simulation using experimental results; a multiscale model of grain growth; a conceptual methodology developing “high-temperature” CCT (continuous cooling transformation) diagrams, and many more examples validating the numerical simulations. The models presented are applied in comprehensive tests in order to solve problems related to the high-temperature deformation of steel. The testing methods include both physical tests using specialist laboratory instruments, and advanced mathematical modelling: the Finite Element method (FE), Smoothed Particle Hydrodynamics method (SPH) and Mo nte Carlo method (MC).This approach, which integrates the fields of physical and computer-based simulations, forms the basis for the described concept of integrated high-temperature process modelling, presented in detail in this book.
The physical modelling of metal forming processes has been widely used both in University and in Industry for many years. Relatively simple numerical models, such as the Slab Method and the Upper Bound Method, were first used and many such models are implemented in the industry for practical design or regulation of forming processes. These are also under investigation in the University, mainly for treat models ments which require low cost calculations or very fast answers for on-line integration. More recently, sophisticated numerical methods have been used for the simulation of metal flow during forming operations. Since the early works in 1973 and 1974, mainly in U. K. and U. S. A. , the applications of the finite element method to metal processing have been developed in many laboratories all over the world. Now the numerical approach seems to be widely re cognized as a powerful tool for comprehension oriented studies, for predic ting the main technological parameters, and for the design and the optlmi zation of new forming sequences. There is also a very recent trend for the introduction of physical laws in the thermo-mechanical models, in order to predict the local evolution of internal variable representing the micro structure of the metal. To day more and more practicians of the Industry are asking for compu ter models for design of their forming processes.
This publication has been written to honour the contribution to science and education made by the Distinguished Professor Emeritus Professor Schey on his eightieth birthday. The contributors to his book are among the countless researchers who have read, studied and learned from Professor Schey's work, which includes books, research monographs, invited papers, keynote papers, scientific journals and conferences. The topics include manufacturing, sheet and bulk metal forming and tribology, amongst others. The topics included in this book include: John Schey and value-added manufacturing; Surface finish and friction in cold-metal rolling; Direct observation of interface for tribology in metal forming; An examination of the coefficient of friction; Studies on micro plasto hydrodynamic lubrication in metal forming; Numerical simulation of sheet metal forming; Geometric and mechanics model of sheet forming; Modelling and optimisation of metal forming processes; The mathematical modelling of hot rolling steel; Identification of rheological and tribological parameters; Oxide behaviour in hot rolling; Friction, lubrication and surface response in wire drawing; and Modelling and control of temper rolling and skin pass rolling.
