Integrated Multiscale Robust Design Considering Microstructure Evolution and Material Properties in the Hot Rolling Process

2014 ◽  
Author(s):  
Chung-Hyun Goh ◽  
Salman Ahmed ◽  
Adam P. Dachowicz ◽  
Janet K. Allen ◽  
Farrokh Mistree
Keyword(s):  
Robust Design ◽  
Microstructure Evolution ◽  
Hot Rolling ◽  
Material Properties ◽  
Prediction Models ◽  
Solution Space ◽  
Rolling Process ◽  
Roll Pass ◽  
Technical Requirements ◽  
Property Performance

A transmission gear is generally produced by a sequence of several processes from steelmaking to final machining and surface treatment. The intermediate processes such as hot rolling induce microstructure evolution and phase transformation which play a significant role in determining the mechanical properties and fatigue strength of gears. Therefore, these intermediate processes should be carefully considered in determining the performance and properties of the end product. In this paper, an integrated multiscale robust design approach using the Inductive Design Exploration Method (IDEM) is implemented to improve robustness in the presence of uncertainty by exploring the solution space in order to find feasible solutions to satisfy technical requirements and/or customer aspirations. Four pass roll design with oval and round grooves is used to simulate the hot bar rolling process. The microstructure evolution, flow stress, and wear prediction models are implemented in the analysis model to account for the process-structure relationship in each roll pass. Surrogate models for some parameters such as ultimate tensile strength are then developed based on the analysis results. Using the relationship of processing-structure-property-performance, the integrated realization of engineered materials and products (IREMP) can be accomplished over multiple length scales. In IDEM, the range of the property-performance relationship is first evaluated by the requirements for the end product. Subsequently, the austenite and ferrite grain sizes and material properties are inductively determined by exploring the design space. Consequently roll pass design including the rolling conditions and the microstructure of billets are customized by the exploration of design variables based on IDEM.

Impact Analysis of Microstructure Evolution in Hot Rolling of H-Beams

2013 ◽  
Vol 652-654 ◽  
pp. 2024-2028
Author(s):  
Wen Ping Liu ◽  
B. Zhang ◽  
Pei Qi Wang ◽  
Qin He Zhang
Keyword(s):  
Microstructure Evolution ◽  
Hot Rolling ◽  
Mechanical Model ◽  
Impact Analysis ◽  
Rolling Process ◽  
Time Interval ◽  
Hot Rolling Process ◽  
Finite Element Package ◽  
H Beam ◽  
Rough Rolling

To improve the product properties of H-beams, it is essential to understand the effects of hot rolling parameters on the microstructure evolution of the beams. For this purpose, a thermo mechanical model was built with the finite element Package ABAQUS. By re-meshing the model, multipass large-deformation hot rolling process was simulated under the boundary conditions predefined in accordance with the practical production. Based on the hot rolling simulation, an impact analysis of strain rate, initial rough rolling temperature, and time interval between passes on the microstructure evolution of H-beam austenite was conducted. The analytical results are meaningful for optimizing hot rolling parameters and improving H-beam properties.

Simulation of Multipass Hot Rolling for 7050 Aluminum Alloys

2016 ◽  
Vol 846 ◽  
pp. 145-150
Author(s):  
Yang An ◽  
Peter Hodgson ◽  
Chun Hui Yang
Keyword(s):  
Aluminum Alloys ◽  
Microstructure Evolution ◽  
Hot Rolling ◽  
Subgrain Size ◽  
Local Strain ◽  
Rolling Process ◽  
Hot Rolling Process ◽  
Mechanical Evolution ◽  
Mechanical Behaviours ◽  
Parametric Studies

To determine the relations between rolling passes, mechanical behaviours and microstructure evolution of AA7050 aluminum alloys, finite element modeling of a multipass hot rolling process is developed and employed to investigate thermo-mechanical evolution during this processing. Through parametric studies, the distribution of local strain and temperature across thickness during the hot rolling process are numerically determined. These results are used to determine the subgrain size and thus the microstructure evolution during the hot rolling process are estimated.

Effect of the Rolling Process on Microstructures and Mechanical Properties of the Extruded LA91 Alloy Sheet

2011 ◽  
Vol 686 ◽  
pp. 90-95 ◽  
Author(s):  
Bin Jiang ◽  
Qing Shan Yang ◽  
Liang Gao ◽  
Fu Sheng Pan
Keyword(s):  
Mechanical Properties ◽  
Microstructure Evolution ◽  
Hot Rolling ◽  
Rolling Process ◽  
Alloy Sheet ◽  
Rolling Reduction ◽  
Thermal Compression ◽  
Cross Rolling ◽  
The Cross ◽  
Rolling Route

The microstructure evolution of the extruded Mg-9Li-1Al (LA91) during rolling was investigated taking account of effects of different routes including hot rolling, and cross rolling. The rolling parameters were suggested by thermal compression testing. As a result, the suggested rolling parameters were 250°C and 1.0s-1. Transverse hot rolling would bring a finer microstructure to the as-rolled LA91 sheet. With the enhancement of the rolling reduction during unidirectional hot rolling the α-Mg phase became granular or short rod-like from long strip-like. Transverse + longitudinal hot rolling would improve the microstructure and was a better cross rolling route by which the strength and the elongation of the cross rolled LA91 sheet reached 243MPa and 20% respectively. The over-aging existed in the cross rolled LA91 sheets.

Three Dimensional Prediction of Microstructure Evolution and Mechanical Properties of Hot Strips

2011 ◽  
Vol 291-294 ◽  
pp. 455-464 ◽  
Author(s):  
Guo Ming Zhu ◽  
Chao Lv ◽  
Yong Lin Kang ◽  
Guo Guang Cheng
Keyword(s):  
Microstructure Evolution ◽  
Prediction Models ◽  
Computational Simulation ◽  
Temperature Drop ◽  
Three Dimensional ◽  
Rolling Process ◽  
Real Situation ◽  
Property Prediction ◽  
C Language ◽  
3D Microstructure

With the 3D thermal mechanical coupled elastic-plastic finite element method and by simulating the whole rolling process of 1250mm×20mm C-Mn hot strips, this paper obtains the temperature field and deformation result of the rolling process. By comparing the temperature drop curve with the measured data in the field, it shows that the simulation result is close to the real situation. Based on the thermal mechanical coupled simulation of the whole rolling process, this paper completes the computational simulation of the prediction of the 3D microstructure and property of hot strips by using the relevant microstructure evolution and property prediction models and advanced C language programming, thus providing reference for the property prediction of new products and processes.

Numerical Simulation of Rolling Process and Microstructure Evolution of AM50 Mg Alloy during Hot Rolling Process

2011 ◽  
Vol 291-294 ◽  
pp. 449-454 ◽  
Author(s):  
Fuan Hua ◽  
Chao Yi Zhang ◽  
Qiang Li ◽  
Bao Yi Yu ◽  
Wei Hua Liu ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Grain Size ◽  
Microstructure Evolution ◽  
Hot Rolling ◽  
Heating Temperature ◽  
Simulation Method ◽  
Rolling Process ◽  
Mg Alloy ◽  
Hot Rolling Process ◽  
Rolling Method

In order to optimize rolling process of AM50 Mg alloy, numerical simulation method is adopted to find reasonable process parameters. And then, the metallograph was viewed to find the microstructure evolution during hot rolling process. Through numerical simulation it is found that while the heating temperature is 420 and the train less than 0.33 each time. Through 10 times rolling, a 10mm thickness plate was rolled to 0.5mm, and its grain size also decreases to 10μm, which indicates that AM50 Mg alloy can be formed by hot rolling method.

Multi-field coupled numerical simulation of microstructure evolution during the hot rolling process of GCr15 steel rod

2011 ◽  
Vol 50 (7) ◽  
pp. 1951-1957 ◽  
Author(s):  
Sen-dong Gu ◽  
Li-wen Zhang ◽  
Chong-xiang Yue ◽  
Jin-hua Ruan ◽  
Jian-lin Zhang ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Microstructure Evolution ◽  
Hot Rolling ◽  
Rolling Process ◽  
Gcr15 Steel ◽  
Hot Rolling Process

Robust Design of Square-to-Box Rolling of Steel Rods

1995 ◽  
Author(s):  
Koji Yoshimura ◽  
Rajiv Shivpuri ◽  
Kosuke Ishii
Keyword(s):  
Robust Design ◽  
Rolling Process ◽  
Design Guidelines ◽  
Lateral Spread ◽  
Empirical Knowledge ◽  
Roll Pass ◽  
Shape Rolling ◽  
Element Simulation ◽  
Minimum Variation ◽  
Roll Gap

Abstract This study seeks a robust design of square-to-box rolling that leads to minimum variation in the geometric profile of rolled workpieces. Variations considered are the workpiece geometry, the roll diameter, and roll gap. The paper focuses on the variation of the workpiece width. The key is to define parameters that correctly reflect the physical characteristics of shape rolling. The study applies the Taguchi method to finite element simulation of rolling process using seven design and process parameters. Sensitivity analysis and comparison with empirical knowledge lead to design guidelines that reduce lateral spread variation in the square-to-box roll pass process.

Precipitation Behavior and Microstructure Evolution of Mg-Zn-Zr-Er Alloy Processed by Secondary Deformation and Heat Treatment

2013 ◽  
Vol 747-748 ◽  
pp. 377-382
Author(s):  
Bao Xiang Zhang ◽  
Jing Zhang
Keyword(s):  
Microstructure Evolution ◽  
Hot Rolling ◽  
Volume Fraction ◽  
Rolling Direction ◽  
Hardness Test ◽  
Secondary Phase ◽  
Rolling Process ◽  
Second Phase ◽  
Precipitation Behavior ◽  
Hot Rolled

Preheated at 673K for 3h and 6h respectively, as-extruded Mg-9Zn-0.6Zr-2Er (wt.%) slabs with starting thickness of 8mm were hot-rolled at 673K to 2mm. The hot-rolled alloys were then solution treated at 673K for1.5h and aged at 473K for 10h. Microstructure evolution and second phase precipitation behavior during hot rolling and subsequent heat treatments were examined by optical microscopy (OM), scan electron microscopy (SEM) and micro hardness test. Mg-9Zn-0.6Zr-2Er alloy were fully recrystallized with fine equiaxed grains after preheating for 3 hours, prolonging heating time leads to a higher degree of dissolution of secondary phase into Mg matrix but a coarsening of the microstructure. During hot rolling process, the volume fraction of the DRX grains increased gradually with increasing reduction ratio, shearing bands became visble in the final pass. Thermal stable Mg-Zn-Er intermetallic compounds distributed along rolling direction at the first rolling passes and became more homogenous in the final pass. More nanosized MgZn2 precipitated during hot rolling in the alloy preheated for 6h than that for 3h, leading to an enhanced precipitation hardening effect in the former.

Exploration of Solution Space to Study Thermo-Mechanical Behavior of AA5083 Al-Alloy During Hot Rolling Process

2017 ◽  
Author(s):  
Anand Balu Nellippallil ◽  
Rishabh Shukla ◽  
Surya Ardham ◽  
Chung-Hyun Goh ◽  
Janet K. Allen ◽  
...  
Keyword(s):  
Process Parameters ◽  
Hot Rolling ◽  
Design Method ◽  
Solution Space ◽  
Rolling Process ◽  
Al Alloy ◽  
Aa5083 Alloy ◽  
Simulation Based Design ◽  
Process Operation ◽  
Set Based Design

A method is proposed to explore the solution space of a metallurgical process with an aim to foster material innovation through simulation based design. The efficacy of the method is demonstrated in the context of hot rolling of the AA5083 alloy. The set-based design approach is employed to predict the process parameters of rolling operation for a given set of specified requirements. Critical process parameters such as strain rate, temperature, heat transfer coefficient and strip width are only considered in the design study. Ternary plots are constructed and utilized to explore the solution space obtained and thereby identifying feasible regions of process operation wherein the specified requirements are satisfied. Since plant data is not available for the study, Finite-element (FE) analysis is carried out as a means to validate the results obtained using aforesaid design method.

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