Synergistic optimization of shape-force and dynamic coupling effect in bending roll systems during accelerated...

Area of Science:

• Materials Science
• Mechanical Engineering
• Manufacturing Processes

Background:

• Dynamic imbalance in rolling force fields during acceleration causes strip thickness fluctuations and shape distortions.
• These defects critically limit high-end cold-rolled product quality and production efficiency.

Purpose of the Study:

• To investigate the coupled effects of Work Roll Bending (WRB) and Intermediate Roll Bending (IRB) on dynamic responses during cold rolling acceleration.
• To develop and validate a composite control strategy for mitigating defects and optimizing production during the acceleration phase.

Main Methods:

• Development of a 3D elastoplastic finite element model of a six-roll continuous cold rolling mill using ABAQUS.
• Systematic analysis of WRB and IRB impacts on strip thickness, flatness, cross-sectional crown, and rolling force.

Main Results:

• Increasing WRB improves thickness distribution and reduces secondary wave defects; increasing IRB enhances uniformity but is less effective for quaternary waves.
• Bending force effectively controls shape fluctuations by optimizing rolling force and inter-roll pressure distribution.
• The proposed composite control strategy (dynamic bending force compensation and tension control) with segmented speed optimization significantly reduces edge waves and improves thickness uniformity during acceleration.

Conclusions:

• A coordinated dynamic shape control system offers theoretical and practical pathways for intelligent process optimization in continuous cold rolling mills.
• Optimizing the acceleration process through dynamic control strategies enhances production efficiency and minimizes losses.