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A Simulation of Roll Wear in Hot Rolling Processes
A thesis submitted in fulfilment of the requirements
for the award of the degree
Master of Engineering
(HONS)
UNIVERSITY OF
UNIVERSITY OF WOLLONGONG
by
Bo Wang
CONTENTS
Acknowledgment
Abstract
Introduction 1
Chapter 1 Literature Survey 4
1.1 Friction and wear 5
1.1.1 Contact and contact force distribution 5
1.1.2 Friction 9
1.1.3 Wear and wear catalogue 12
1.1.4 Summary of wear equation and prediction 17
1.1.5 Influence factors and variables of rolling wear 20
1.2 Rolls in rolling mill 21
1.2.1 Classification of rolls in rolling mill 21
1.2.2 Required properties of rolls 22
1.2.3 Application of rolls 24
1.3 Hot roll wear modes 27
1.3.1 Banding 29
1.3.2 Abrasion 32
1.4 Influence factors of hot roll wear 34
Chapter 2 Design of Hot Rolling Wear Test Rig 38
2.1 General design 39
2.1.1 Selection of test geometry 39
2.1.2 Outline of the wear test rig 412.1.3 Input and output parameters of the rig 43
2.2 Heating and insulating design 44
2.2.1 Heating method 44
2.2.2 Heating disk design 45
2.2.3 Heating element 47
2.2.4 Insulation design 47
2.3 Electric brushes design 48
2.4 Roller and its support design 51
2.5 Consideration of parameter measurement 56
2.5.1 Capacitance sensor 56
2.5.2 Thermocouple 58
2.5.3 Load cell 59
2.5.4 Optoelectrical sensors 59
2.5.5 Acoustic emission sensor 60
2.6 Cooling design 60
Chapter 3 General Design of Measurement and Control System 63
3.1 Measurement and control system based on computer 64
3.2 Real-time programming 65
3.3 Calibration method 67
3.3.1 Calibration method 67
3.3.2 Calibration curve fitting and interpolation 68
3.4 General design of the system 71
Chapter 4 Hardware Design of Measurement and Control System 7
4.1 Data logging board 75
4.2 Analog interface design 774.2.1 Sensors and instruments 77
4.2.2 Signal conditioners and interface circuits 85
4.3 Digital interface design 88
4.3.1 General design 88
4.3.2 Digital interface circuits 90
4.4 Data logging board configuration and interface channel assignment 97
4.4.1 Data logging board configurations 97
4.4.2 Interface channel assignment 98
Chapter 5 Software Design of Measurement and Control System 101
5.1 General design 102
5.2 MacAdios II board diagnosis process 106
5.2.1 A/D and D/A check 109
5.2.2 DI and D O check 113
5.2.3 Timer/counter check 115
5.3 Calibration process 118
5.4 Pre-adjustment process 127
5.5 Experimental/simulation process 131
5.5.1 Screen setting 131
5.5.2 M e n u setting 134
5.5.3 General operation process 137
Chapter 6 Experiments and Discussions 147
6.1 Experimental procedure 150
6.2 Preliminary test of the rig 152
6.3 Experiments and discussions 162
6.3.1 Experiments 1626.3.2 Discussions 170
Chapter 7 Conclusions and recommendations 174
7.1 Conclusions 175
7.2 Recommendations for future work 176
References 178
Appendices 185
Appendix A Properties of 2 5 3 M A steel 186
Appendix B Discussion on accuracy of measurement 187
Appendix C Properties of MacAdios JJ data logging board 191
Appendix D List of the integrated software 193
Appendix E Calibrations of sensors 321
Appendix F Control curve of temperature 326
Appendix G Transfer of printing figure
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