Simufact forming for Steel Industry

Classic rolling theory

… more than 90 different approaches … each with specific strengths and

weaknesses … which shall I take?

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Pro‘s and Con‘s of classic theory
Advantages (Pro‘s)
◆ Fast (analytical equations)
◆ Can be used to make serial examinations
◆ Main tool for pass schedule prediction

Disadvantages (Con‘s)
◆ Only valid for plane strain conditions
◆ Not useful if triaxial states occur
(groove rolling, bending, distortion, …)
◆ Some geometrical details cannot be predicted
(i.e. edge formation)
◆ Gives no information on local measures
-> local distribution of micro-structure and local
properties are not predictable
◆ Incremental elastic response of both roll stand
and rolls is not possible (or only very limited)
◆ Side processes or even previous or following processes
cannot be chained (other applications then rolling)

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Classic rolling theory

… wish there would be the „All-in-one“ solution …

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Hybrid approach

… what if … I would use Finite Element

software as a complementary tool?

Could Simufact help me?

… Franz-Dieter Philipp asks?

XXXIV. Verformungskundliches Kolloquium 5

Inputs for accurate predictive FE models

Material-
parameters

Contact &
Element type Friction

Elastic responses
of the whole Elastic-Plastic
system material law

Thermo-
Kinematics mechanical
coupling

Never forget: the GARBin – GARBout principle!!!

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 Hot Rolling

ROLLING

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Process Chains
Rolling – considering casted micro-structure

Courtesy: MagmaSoft (this example: ingot casting)

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 Simufact.forming
Aim of benchmark Simulation Manufacturing

◆ Hot Rolling of casted bloom 320 x 400 mm

to 240 x 331 mm (4 passes)
◆ To show capability of Simufact.Forming in terms
of micro-structural analysis, especially grain size
evaluation in general
◆ Please note: important input data are not
measured but they are a guess
◆ Model must be adapted and calibrated to real
data from shop floor
FORMING PROCESS
 Simufact.forming
Customer Process Scheme Simulation Manufacturing
Pass %
Sr. Rotation Approx. Cross-
Width Reductio
No. before pass section after pass
(mm) n per pass
1 320 90⁰ Rotation 320 X 348 13

2 320 320 X 331 5

3 320 90⁰ Rotation 288 X 331 10

4 320 240 X 331 17

➢ Material: 1.4541
➢ Initial grain size: up to 1.5 mm (columnar
grain with aspect ratio: 1:4 (dia:length) ) ->
assumption for simulation: uniform initial
grain size of 900 µm
➢ Initial temperature before entering pass 1:
1206°C (measured)
➢ Roll geometries and pass schedule as per
customer input

Input Data
 Simufact.forming
Roll Forces Simulation Manufacturing

Pass 1: appr. 650…700 t max. Pass 2: appr. 450…475 t max.

Pass 3: appr. 600…675 t max. Pass 4: appr. 770…810 t max.

Results
 Simufact.forming
Whole model Simulation Manufacturing

- 2 rolls (upper/lower)
- 24 active rollers (roller table)
- 2 guiders (invisible mode)

Initial stage
 Simufact.forming
Animation Simulation Manufacturing

All Passes - Temperature

Modeling – cooling before pass1# Simufact.forming
Simulation Manufacturing

Calculated temperature after transportation

and before entering pass 1#

Temperature before pass 1

Modeling – pass 1# Simufact.forming
Simulation Manufacturing

Pass 1: temperature global

Modeling – pass 1# Simufact.forming
Simulation Manufacturing

Pass 1: equiv. strain outer face

Modeling – pass 1# Simufact.forming
Simulation Manufacturing

Pass 1: equiv. strain core

Modeling – pass 1# Simufact.forming
Simulation Manufacturing

Grain size: global

Modeling – pass 1# Simufact.forming
Simulation Manufacturing

Grain size: cross section

Modeling – pass 1# Simufact.forming
Simulation Manufacturing

Centre loseness
Modeling – pass 3# Simufact.forming
Simulation Manufacturing

Centre loseness closed after pass 3#

Modeling – pass 4# Simufact.forming
Simulation Manufacturing

Grain size: global

Modeling – pass 4# Simufact.forming
Simulation Manufacturing

Grain size: cross section

Elastic responses
Elastic responses
of the whole
system

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Elastic responses
Elastic responses Scan real shape Simulated …
of the whole
system

…with elastic …with rigid

roll stand roll stand

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Groove rolling @ Mannstaedt GmbH

Goal: to analyse and to control local distribution of field

variables as well as global integral quantities

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Cold Rolling

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Elastic responses
Elastic responses
of the whole
system

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Cold rolling of Aluminium sheet

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Rolling of Aluminium sheet

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Elastic responses

Calculated roll gap contour of foil roller

Elastic-plastic characteristics of rolling

mill and rolling stock

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Elastic responses
Elastic responses
of the whole
system
Bearings with
rotational DOF‘s

work rolls -deformable

Stress distribution and displacement of

elastically deformed (bended) work rolls

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Distortion of a rim profile – before

Elastic-Plastic
material law

Simulation: not only

behaviour inside roll gap but
also elastic deformation of
rolled stock after roll stand

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Distortion of a rim profile - optimized

Elastic-Plastic
material law

Original distorted shape

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Optimization of a fork carrier

Elastic-Plastic
material law

Minimizing distortion
by axial offset of
upper roll

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Heat Treatment

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Advanced bevel gear manufacturing
◆ Process design for the bevel gear wheel
▪ Forming strategy
▪ Die design
▪ Fine and homogeneous 1200

Temperature in °C

Strain
Microstructure (xRX, GG)
680

RT
Considered in simulation Process time
sequence

Source: IBF, RWTH Aachen

© simufact engineering gmbh 38

Module Recrystallization
◆ Fine and homogenous grain sizes distribution is gained (customer spec)

Source: IBF, RWTH Aachen

© simufact engineering gmbh 39

Heat Treatment

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Simufact Quenching Process
Quenching crack
Objective:
 Eliminate quenching
cracks
 Avoid excessive
quenching distortion
Benefits:
 Reduced scraps

Quenching distortion Simufact drives process change

to eliminate quenching cracks

© simufact engineering gmbh Page 41

Which depth of Modelling?
100 10-2 10-3 10-4 10-5 10-6 10-8 10-10
makro meso micro nano
m cm mm m nm

Simufact.premap concept
global local
multi-phase poly- slip
homogeneous homogeneous crystal dislocations
materials crystalline systems
continuum continuum

R
forces, work, local phase microstructure: crystal texture, dislocation atomistic
moments, deformation, transformation, grain size, crystal density, deformation
avg. temper., strain rate, phase grain growth, anisotropy particle mechanisms
efficiency stresses, boundaries orientation hardening
temperature recrystallization

R. Kopp: „Innovation in Steel“, 65th Anniversary of Instytut Metalurgii Żelaza im. St. Staszica, Poland, 29th April 2010

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Macrolevel or Nano?

Material-
parameters

StrucSim: calculation of substructures & statistical

distribution of grain sizes and their impact on mechanical
properties (i.e. flow stress)

Only one aspect among many others:

During hot forming a certain number of several micro-substructures (S1, S2, S3) are
created due to SRX, DRX, nucleation & grain growth -> hence: for appropriate
calculations one need to consider their different properties = dynamic &
incremental closed loop within solver

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The MKS Approach

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Texture & morphology prediction

High purity Ti
with clock-
rolled starting
texture.

Center morphology after

50% reduction ratio

Surface morphology
after 50% reduction ratio

Based on technology

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Fast computations …

◆ Multiple CPU-cores
◆ Flexible Decomposition-Methods
◆ Fast statistics
◆ Scale-bridging (Nano -> Makro)

… all-embracing development of „speed-up“

technologies, i.e. dynamic multi-job and multi-node
management, fast statistics, …

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Existing Customers

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Thanks a lot for listening!
simufact engineering gmbh
Tempowerkring 19
21079 Hamburg, Germany
Tel.: +49 (0)40 790 128 - 000
Fax: +49 (0)40 790 128 - 199
info@simufact.de
www.simufact.com