Presentation by

TOPY Industries, Limited

Kazuki Mori

1

26, JUNE, 2018

General Section Steel

2

Vertical and bilateral

symmetry

bilateral symmetry

Flat bar

Equal Leg

Angles Channels

Rolling Material

Upper Roll

Lower Roll

Transform

Rolling Direction

Rolling Process

H-beam

3

Plasticine

model test

Lead

model test

FE

Simulator

(Analysis) Within 1days

1 week

1.5 month

Numerical analysis early

cost = 0 precisely

roll cost

2～3 persons

Comparison of analysis time

Test time Cost, Man power

4

FEM analysis

1/2 or 1/4 model analysis

fewer elements

FEM mesh

Short analysis time

Fine mesh

High Analysis accuracy

Roll contour

Element

1/4model of H-beam

Special section steel

Asymmetry shape

Rim bar Track Shoe bar Mast rail bar

Long Time

1/1 model

Low Accuracy

5

Analysis be

6

by Professor

Yanagimoto

In 1992

１．To analyze the Special sections(1/1model)

２．High precision

３．Analysis Speed

４．Simplicity

５．To fix the rolling phenomena volume

TOPY CORMILL SYSTEM

Goals of the system

Computational Rolling Mill System ：CORMILL SYSTEM

TOPY CORMILL SYSTEM

Modified for our products

7

temperature

gap

Roll diameter FEM

Caliber profile Material profile

before rolling

Rolling

condition

Compression of file

2D･3D

Geometry

Stress

Strain

Distribution

Load・torque

thrust load

bending at exit

Characteristic

value

Meshed profile

Flow of the system

8

entrance height = 0 Entrance height =+15

(automatic adjustment)

１５

The lead

model RD

Influence of Entrance position

Not touched

area

9

1 CPU Intel core-i7-8700k 4.9GHz 2 OS Window 10 3 FORTRAN Intel Fortran 4 MEMORY 16 GB

5 2 dimension CAD FCADWIN 6 3D visual soft Micro AVS

In 2017 4,5000 elements or more

In 2010 30,000 elements or below

Environment

0.0

0.5

1.0

1.5

2.0

2.5

3.0

1995 2000 2005 2010 2015 2020

Analy

sis

tim

e(h

r)

Year

10

1/1model

6,720 elements

853 ＭＢ

2.6 hr

0.4 hr

Transition of analysis time

11

7pass

1pass 4pass 6pass

2pass 5pass

3pass

Analysis Result of Unequal Angles

Each pass analysis separately Possible

12

Application example for existing product ・Conventional process

・Improved process

B D

Mill

R

Mill

Mill

Mill

MIll

Mill

Pace：74sec. / piece

Pace：84sec./ piece

B D

Mill

Mil

l

Mill

Mill

Mill

Mill

Mill

material

material

product

product

Total: 18 Passes

Total: 14 Passes

Reversing：3pass BreakDown:9pass

:Roling pass

BreakDown:7pass 1pass

Improved Productivity

13

1. R-size inside a roll is small,

(currently difficult)

2. More Simplification of pre-processing

3. Quantification for such phenomena,

Flapping, Roll abrasion, Baking

Policy in the future

14

Thank you for your attention

15

entrance

top

bottom

the upper left with slant the upper right with slant

left side right side

The CAD of figure 3dimension

exit

16

before

improvement

after

improvement

Analysis example ； the warp measure by BD

17

0

500

1,000

1,500

2,000

2,500

3,000

3,500

4,000

92 93 94 95 96 97 98 99 0 1

Transition of the number of analysis

YEAR

18

The rolling transfortation of unequal-angle

19

Development of special section steel

Rolling products

Designing Roll caliber