Transfer behaviors and evolution of surface micromorphology of non-smooth strip in temper rolling process with rough roller
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摘要: 針對平整軋制過程不同用途帶鋼對表面微觀形貌的特殊要求，在批量跟蹤電火花毛化軋輥、磨削軋輥和冷軋后帶鋼表面微觀形貌的基礎上，建立工作輥與帶鋼都可考慮真實表面粗糙峰的帶鋼表面微觀形貌軋制轉印生成模型，采用工業實驗驗證了仿真模型的準確性，并據此模型分析軋制前帶鋼已經具有表面粗糙度分別大于、等于、小于軋輥表面粗糙度時，帶鋼表面微觀形貌的軋制轉印行為與遺傳演變規律。提出了負轉印和轉印飽和的概念，定義了兩種極限軋制轉印狀態的描述指標— —負轉印最大和轉印飽和，研究發現當帶鋼表面粗糙度小于或等于軋輥表面粗糙度時，存在負轉印最大點和轉印飽和點；當帶鋼表面粗糙度大于軋輥表面粗糙度時，負轉印最大點和轉印飽和點重合。在此基礎上，采用負轉印最大點與轉印飽和點對應的臨界板寬軋制力，描述帶鋼表面微觀形貌的遺傳及演變規律，并系統仿真分析帶鋼屈服強度、帶鋼軋前表面粗糙度、軋輥表面粗糙度等工藝條件參數對于負轉印最大點與轉印飽和點對應的臨界單位板寬軋制力的影響規律，發現隨著帶鋼屈服強度增大和軋輥表面粗糙度增加，該臨界單位板寬軋制力均增大；隨著帶鋼表面粗糙度增大，負轉印最大點對應的臨界單位板寬軋制力增大，但轉印飽和點對應的臨界單位板寬軋制力卻減小。Abstract: To meet special requirements and respond to control problems of surface micromorphology of different strips in skin rolling process, a rolling transfer generation model of the surface micromorphology contact between work roll and actual rough surface of strip was established on the basis of batch tracing the surface micromorphology of electric discharge textured roll, grinding roll and cold rolled strip. The inheritance and evolution of surface micromorphology of the strip was analyzed based on the generation model and the accuracy of the generation model was verified by industrial experiments. The concepts of negative transfer and transfer saturation were proposed, and the descriptive indicators for two extreme rolling transfer status (the maximum negative transfer and transfer saturation) were defined. When strip surface roughness is equal to or less than that of roll, a maximum negative transfer point and transfer saturation point exist, while when strip surface roughness is greater than that of roll, the maximum negative transfer point is in superposition with the transfer saturation point. Under the above precondition, through the rolling force of critical strip width, which corresponds to the maximum negative transfer point and transfer saturation point, the inheritance and evolution of surface micromorphology of the strip were characterized. The effect of strip yield strength, strip surface roughness, and roll surface roughness on the rolling force of critical strip width corresponding to maximum negative transfer point and transfer saturation point were also analyzed. Results show that with the increase of strip yield strength and roll surface roughness, the rolling force of critical strip width corresponding to maximum negative transfer point and transfer saturation point increases. With the increase of strip surface roughness, the rolling force of critical strip width corresponding to maximum negative transfer point increases, and the rolling force of critical strip width corresponding to transfer saturation point decreases.
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圖 1 不同加工方式工作輥軋制帶鋼表面三維微觀形貌。（a）電火花加工；（b）磨削加工
Figure 1. Three-dimensional micromorphology of strip surface rolled by work roll with different machining methods: (a) electrical discharge machining; (b) grinding machine
圖 2 兩種典型帶鋼表面微觀形貌軋制與板寬方向二維輪廓。（a）電火花加工；（b）磨削加工
Figure 2. Two-dimensional profile along the width and rolling direction of two kinds of typical strip surface microtopography: (a) electrical discharge machining; (b) grinding machine
圖 3 平整軋制過程粗糙工作輥與非光滑帶鋼軋制轉印模型。（a）三維模型；（b）局部放大圖
Figure 3. Three-dimensional model of rolling transfer of rough work roll and non-smooth strip during flat rolling: (a)three-dimensional model; (b) partial enlarged drawing
圖 4 工作輥與帶鋼二維平面仿真模型。（a）平面壓入幾何模型；（b）有限元仿真網格劃分
Figure 4. Two-dimensional plane simulation model of work roll and strip：(a) geometric model of two-dimensional profile plane pressing on strip surface; (b) mesh generation of finite element simulation
圖 5 不同軋制力下帶鋼表面粗糙度遺傳和演變規律
Figure 5. Inheritance and evolution of strip surface roughness under different rolling forces
圖 6 不同單位板寬軋制力下帶鋼與工作輥的位移場分布。（a）帶鋼尖峰擠壓；（b）軋輥尖峰壓入；（c）軋輥凹坑填充；（d）軋制轉印飽和
Figure 6. Displacement field distribution of strip and work roll under different rolling forces: (a) strip peak extrusion; (b) roll peak extrusion; (c) roll pit filling; (d) rolling transfer saturation
圖 7 平整軋制過程帶鋼表面微觀形貌遺傳和演變規律示意圖
Figure 7. Diagram of the inheritance and evolution of strip surface micromorphology in the process of flat rolling
圖 8 工作輥Ra > 帶鋼Ra時不同影響因素對負轉印最大點對應臨界單位板寬軋制力的影響。（a）工作輥表面粗糙度；（b）入口帶鋼表面粗糙度
Figure 8. Influence of different factors on the critical rolling force per unit width at the maximum point of negative transfer when work roll Ra > strip Ra: (a) surface roughness of the work roll; (b) surface roughness of inlet strip
圖 9 工作輥表面二維輪廓支撐長度率曲線
Figure 9. Support length ratio curve of two-dimensional contour of work roll surface
圖 10 工作輥Ra > 帶鋼Ra時不同影響因素對軋制轉印飽和點對應臨界單位板寬軋制力的影響。（a）工作輥表面粗糙度；（b）入口帶鋼表面粗糙度
Figure 10. Influence of different factors on the critical rolling force per unit width at the saturation point of rolling transfer when work roll Ra > strip Ra: (a) surface roughness of the work roll; (b) surface roughness of inlet strip
圖 11 工作輥Ra < 帶鋼Ra時不同影響因素對轉印飽和點對應臨界單位板寬軋制力的影響
Figure 11. Influence of different factors on the critical rolling force per unit width at the saturation point of rolling transfer when work roll Ra < strip Ra
圖 12 工作輥Ra = 帶鋼Ra時不同軋制力下帶鋼表面微觀形貌的遺傳和演變規律
Figure 12. Inheritance and evolution of strip surface morphology under different rolling forces when work roll Ra = strip Ra
表 1 兩種典型帶鋼表面微觀形貌軋制與板寬方向二維輪廓粗糙度參數
Table 1. Roughness parameters of two-dimensional profile along the width and rolling direction of two kinds of typical strip surface microtopography
Roughness parameters Coordinatesaxis Electrical discharge machining Grinding machine 1 2 3 4 Mean value 1 2 3 4 Mean value Ra/μm X-axis 1.18 1.02 1.05 0.99 1.06 0.58 0.57 0.49 0.52 0.54 Y-axis 1.21 1.04 1.01 1.08 1.08 0.32 0.22 0.34 0.20 0.27 Rz/μm X-axis 5.78 5.82 5.89 6.43 5.98 4.23 4.37 4.82 5.10 4.63 Y-axis 6.21 5.97 6.05 6.20 6.11 2.01 2.34 2.81 2.45 2.40 Ry/μm X-axis 6.09 5.98 6.05 6.45 6.14 4.35 4.43 4.87 5.14 4.70 Y-axis 6.30 6.28 6.12 6.39 6.27 2.10 2.44 3.01 2.76 2.58 Pc/cm?1 X-axis 60 45 56 52 53 97 82 87 80 87 Y-axis 55 55 43 50 51 107 95 117 90 102 
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表 2 工業實驗工況表
Table 2. Industrial experiment condition
Working
conditionIncoming strip
Ra/μmWork roll
Ra/μmRolling force/
(kN?mm?1)1 0.63 2.45 2.0 2 0.63 2.45 2.5 3 0.67 3.03 2.0 4 0.67 3.03 2.5 5 0.67 3.03 3.0
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表 3 模型計算帶鋼表面粗糙度參數與實驗實測值對比
Table 3. Comparison between model calculation parameters of strip surface roughness and experimental values
Working condition Ra/μm Rz/μm Ry/μm Pc/cm?1 M C A R/% M C A R/% M C A R/% M C A R/% 1 1.034 1.093 0.059 5.71 4.244 4.464 0.220 5.18 4.251 4.501 0.250 5.88 68 70 2 2.94 2 1.203 1.255 0.052 4.32 5.973 5.826 0.147 2.46 5.997 5.844 0.153 2.55 70 70 0 0 3 1.155 1.135 0.020 1.73 5.322 5.128 0.194 3.65 5.394 5.202 0.192 3.56 62 60 2 3.23 4 1.262 1.284 0.022 1.74 5.748 5.889 0.141 2.45 5.852 5.922 0.07 1.20 66 60 6 9.09 5 1.451 1.440 0.011 0.76 7.592 7.846 0.254 3.35 7.607 7.861 0.254 3.34 65 60 5 7.69 Note：M—measured value；C—calculated value；A—absolute error；R—relative error.
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表 4 帶鋼表面粗糙度遺傳和演變規律計算工況
Table 4. Calculation condition of genetic and evolution rule of strip surface roughness
Working condition Strip Ra/μm Work roll Ra/μm Work roll Ra > Strip Ra 1 3.5 Work roll Ra ≈ Strip Ra 1 1 Work roll Ra < Strip Ra 1 0.5
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