Method for controlling rolling surface roughness of laser texturing working rollers of four-roller aluminum cold-rolling mill

Abstract

The invention relates to a method for controlling the rolling surface roughness of a laser texturing working roller of a four-roller cold-rolling aluminum mill, which is characterized by comprising the following steps of: S1, carrying out a rolling test on aluminum strips and aluminum strip rollers with different specifications before production, and establishing a rolling force-time-roughness mapping relation model; s2, the rolling reduction of the aluminum strip is simulated and optimized through finite elements, and dynamic adjustment is conducted in combination with real-time thickness monitoring; s3, the roll bending force is adjusted according to the plate shape change of the aluminum strip and the associated database; stable tension is maintained through a tension sensor; the rolling speed is optimized by combining materials and equipment performance; and S4, ensuring that the surface roughness of the aluminum strip is stable and meets preset requirements through real-time monitoring and cooperative control models of the parameters. According to the method, the calibration rolling force, the calibration time and key parameters such as the rolling reduction, the bending roller, the tension and the rolling speed in the production process are optimized and adjusted, and it is ensured that the surface roughness of the produced strip meets the preset requirement.

Description

Technical Field The invention relates to the technical field of aluminum cold rolling processing, in particular to a method for controlling the rolling surface roughness of laser texturing working rolls of a four-roll aluminum cold rolling mill. Background Art In aluminum cold rolling production, the surface roughness of the strip has a significant impact on its subsequent application; for example, in applications such as electronic device casings and packaging materials, strict surface roughness requirements are imposed on aluminum strip. Laser texturing of work rolls has been widely used in aluminum cold rolling mills to improve strip surface quality. However, in actual production, even if the roll roughness and the initial condition of the rolling equipment are acceptable, ensuring that the surface roughness of the produced strip meets the requirements still faces many challenges. Summary of the Invention In view of the above-mentioned deficiencies in the prior art, the purpose of the present invention is to provide a method for controlling the rolling surface roughness of the laser-textured working rolls of a four-roll aluminum cold rolling mill. Without considering the grinding process and the original quality of the rolls, the method ensures that the surface roughness of the produced strip meets the predetermined requirements by optimizing and adjusting key parameters such as the calibrated rolling force, the calibrated time, and the reduction amount, bending roll, tension, and rolling speed during the production process.

[0001] The present invention provides a method for controlling the rolling surface roughness of a laser-textured work roll of a four-roll aluminum cold rolling mill, which is characterized by: Step S1: before production, rolling tests are conducted on aluminum strips and aluminum strip rollers of different specifications to establish a rolling force-time-roughness mapping relationship model; Step S2: Optimizing the rolling reduction of the aluminum strip using finite element simulation, and dynamically adjusting it in combination with real-time thickness monitoring; Step S3: adjusting the bending roll force according to the shape change of the aluminum strip and the associated database; maintaining stable tension through the tension sensor; optimizing the rolling speed in combination with the material and equipment performance; Step S4: Through real-time monitoring of various parameters and collaborative control model, ensure that the surface roughness of the aluminum strip is stable and meets the predetermined requirements.

[0002] Furthermore, in step 1, before production, for aluminum strips and aluminum strip rollers of different specifications, the rolling force, time and surface roughness data are recorded through multiple rolling tests to construct a mapping relationship model; in actual production, the model is queried according to the target roughness, the initial rolling force and time parameters are set, and real-time monitoring is carried out through pressure sensors and timers. When the rolling force fluctuation exceeds ±50kN, the hydraulic system of the aluminum strip roller is automatically adjusted to ensure that the parameters are stable within the set range.

[0003] Furthermore, step 2 is to analyze the effects of different reductions on deformation, stress distribution and roughness based on the material, initial thickness and target thickness of the aluminum strip using finite element simulation software to select the optimal reduction for rolling the aluminum strip. During the rolling process, the reduction device is used for precise control and real-time monitoring of the strip thickness. When the deviation exceeds ±0.01mm, the reduction is dynamically fine-tuned. At the same time, the chain effect on rolling force and speed is comprehensively considered for coordinated optimization.

[0004] Furthermore, in step 3, the force value is monitored in real time through the bending roll force sensor, the bending roll force is adjusted in combination with the change in the plate shape of the aluminum strip, and a bending roll force-plate shape-roughness correlation database is established. According to the real-time measurement results of the surface quality of the aluminum strip, the optimal adjustment strategy is matched from the database to ensure that the plate shape is improved without affecting the roughness.

[0005] Furthermore, in step 3, the initial tension is set according to the specifications of the aluminum strip, and the tension sensors of the uncoiler and coiler are used for real-time monitoring. When deviation occurs and causes tension fluctuations, the motor speed is adjusted to maintain the tension within the range of 80kN±5kN. That is, by optimizing the tension, the flatness of the strip and the risk of tensile deformation are balanced to avoid roughness abnormalities caused by unstable tension.

[0006] Furthermore, in step 3, the initial rolling speed is determined based on the material, roll wear and equipment performance, and the surface quality of the aluminum strip is monitored in real time. When uneven roughness occurs, the rolling speed is dynamically adjusted.

[0007] Furthermore, in step 4, the rolling force, reduction, bending roll force, tension, and speed parameters are monitored and adjusted dynamically in real time through the established parameter association models and databases. When a certain parameter fluctuates, the system automatically triggers the collaborative optimization of the associated parameters, quickly adapting to production changes caused by material differences and equipment fluctuations, so as to achieve precise control of surface roughness throughout the entire process.

[0008] Advantages of the present invention: Through the control method of the present invention, the key parameters in the rolling process can be comprehensively and systematically optimized and adjusted based on the default roll roughness and rolling equipment, thereby effectively improving the control accuracy of the strip surface roughness, so that the surface roughness of the produced strip can stably meet the predetermined requirements, improving product quality, and meeting the strict requirements of different application fields for the surface quality of aluminum strips.

[0009] The method of the present invention is based on real-time monitoring and dynamic adjustment of various parameters, and can quickly adapt to various changes in the production process, such as slight differences in strip material, fluctuations in equipment operation, etc., thereby improving the stability and reliability of the production process, reducing the scrap rate, lowering production costs, and improving the production efficiency and economic benefits of the enterprise.

[0010] The established parameter association models and databases provide data support and decision-making basis for the optimization of the aluminum cold rolling production process, help enterprises realize intelligent production management, and promote technological progress in the aluminum cold rolling industry. DETAILED DESCRIPTION The present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0011] The detailed scheme of the method for controlling the rolling surface roughness of the laser texturing work rolls of the four-roll aluminum cold rolling mill of the present invention is as follows: 1. Calibrate the rolling force and time. Before production, conduct multiple rolling tests under standard rolling conditions for aluminum strips and rolls of different specifications using pressure sensors and timers. Record the rolling force versus time curve and the corresponding strip surface roughness measurement values ​​for each test. Establish a rolling force-time-roughness mapping model through data analysis. For example, for a certain type of aluminum strip with a thickness of 0.5 mm, when the rolling force is F1, the strip surface roughness is Ra1 after time t1; when the rolling force is F2, the strip surface roughness is Ra2 after time t2, and so on. Obtain multiple sets of data points to build the model.

[0012] 2. Optimizing Reduction: Based on the material properties, initial thickness, and target thickness of the aluminum strip, combined with the equipment parameters of the product's rolling mill, finite element simulation software is used to simulate and analyze the rolling process under different reductions. The deformation, internal stress distribution, and final surface roughness of the strip under various reduction conditions are predicted. For example, for a specific aluminum alloy strip, the simulation results show that when the reduction is Δh1, the surface roughness of the strip is relatively uniform and meets the requirements; when the reduction is Δh2, the strip surface may exhibit localized roughness anomalies.

[0013] In actual production, the appropriate reduction amount is selected based on the simulation results. During the rolling process, the reduction amount is precisely controlled by the rolling mill's reduction device, and the thickness change of the strip is monitored in real time. If the deviation between the actual strip thickness and the target thickness is found to exceed the allowable range, the reduction amount is fine-tuned in a timely manner. At the same time, the impact of the reduction amount adjustment on other parameters such as rolling force and rolling speed is considered, and comprehensive optimization is carried out to ensure the stability of the strip surface roughness.

[0014] 3. Bending Roll Adjustment: During the mill's operation, a bending roll force sensor monitors the roll force in real time. The mill's bending roll control system adjusts the force based on the strip's width, thickness, and shape changes during rolling. For example, when strip defects such as center or edge waves appear, the bending roll force is appropriately increased or decreased to improve the strip's shape. Research has also found that changes in the bending roll force can affect the strip's surface roughness. Therefore, when adjusting the bending roll force, comprehensive consideration must be given to the real-time measurement of the strip's surface roughness.

[0015] 4. Establish a database of the relationship between bending roll force, strip shape and surface roughness: By collecting and analyzing a large amount of production data, summarize the relationship between bending roll force and strip surface roughness under different working conditions. In actual production, according to the strip shape and surface roughness requirements, query and determine the appropriate bending roll force adjustment strategy from the database to achieve indirect control of the strip surface roughness.

[0016] 5. Tension adjustment: According to the material, specifications and rolling process requirements of the aluminum strip, set the appropriate initial tension on the uncoiler and coiler. During the rolling process, use the tension sensor to monitor the tension changes of the strip in real time. If the tension fluctuates, adjust the motor speed of the uncoiler and coiler to keep the strip tension stable. For example, when the strip deviates during the rolling process, it may cause the tension to change. At this time, adjust the tension in time to avoid adverse effects on the surface roughness of the strip due to unstable tension.

[0017] Research on the variation of strip surface roughness under different tension conditions has revealed, through experiments and production practice, that appropriately increasing tension can improve the strip's surface flatness to a certain extent, thereby affecting surface roughness. However, excessive tension may cause problems such as tensile deformation in the strip, which in turn affects surface quality. Therefore, in actual production, the tension is optimized and adjusted according to the specific conditions of the strip to achieve effective control of the strip's surface roughness.

[0018] 6. Rolling speed optimization: Based on the material of the aluminum strip, the wear of the rolls, and the performance limitations of the rolling equipment, combined with other parameters such as rolling force and reduction, the appropriate rolling speed range is determined through theoretical calculation and experimental verification. During the rolling process, the operating status of the rolling mill and the surface quality of the strip are monitored in real time. If abnormal roughness of the strip surface is found, such as uneven roughness or exceeding the allowable range, the rolling speed is adjusted appropriately. For example, when defects such as local scratches appear on the strip surface, the rolling speed is reduced to observe whether the defects are improved. At the same time, the impact of the rolling speed adjustment on other parameters is analyzed for comprehensive optimization.

[0019] A collaborative control model for rolling speed and other parameters (such as rolling force and rolling oil parameters) was established. In actual production, this model is used to synchronously adjust the rolling speed and other related parameters based on the real-time quality of the strip and process requirements, ensuring stable control of strip surface roughness while maintaining production efficiency.

[0020] Example 1 - Rolling of aluminum strip for a certain type of electronic equipment housing: Rolling force and time calibration: For this type of aluminum strip with a thickness of 0.3mm and a width of 1000mm, laser-textured work rolls with surface roughness that meets the standard were selected. Ten sets of rolling tests were conducted under standard rolling conditions, and the rolling force, time, and strip surface roughness were recorded for each set of tests. For example, in the first set of tests, the rolling force was set to 1000kN, the rolling time was 120s, and the strip surface roughness was measured to be Ra0.8μm. In the second set of tests, the rolling force was set to 1100kN, the rolling time was 110s, and the strip surface roughness was Ra0.75μm. etc., and established a rolling force-time-roughness mapping relationship model suitable for the strip of this specification through fitting analysis of these data; in actual production, the target strip surface roughness requirement is Ra0.7-0.8μm, and the appropriate rolling force setting value is obtained according to the model query, which is 1050kN, and the expected rolling time is 115s; during the rolling process, the rolling force is monitored in real time by a pressure sensor. When the rolling force fluctuation range exceeds ±50kN, the hydraulic system of the rolling mill is automatically adjusted to restore the rolling force to about 1050kN; at the same time, the rolling time is precisely controlled by a timer to ensure that the rolling process is completed in about 115s.

[0021] Optimization of reduction: Finite element simulation software was used to simulate the rolling process of the strip at different reductions. The simulation results showed that when the reduction was 0.08mm, the strip deformed evenly and the surface roughness met the requirements. In actual production, the reduction was precisely set to 0.08mm through the reduction device of the rolling mill, and the strip thickness was monitored in real time using a thickness gauge during the rolling process. If the actual strip thickness deviated from the target thickness (0.3mm) by more than ±0.01mm, the reduction was fine-tuned according to the direction and size of the deviation. For example, when the actual strip thickness was 0.31mm, the reduction was appropriately increased; when the actual strip thickness was 0.29mm, the reduction was appropriately reduced. At the same time, the impact of the reduction adjustment on the rolling force and rolling speed was comprehensively considered for coordinated optimization.

[0022] Bending roll adjustment: During the rolling process, a bending roll force sensor monitors the bending roll force in real time. If a slight wave is detected in the strip, the mill's bending roll control system appropriately increases the bending roll force from an initial 150kN to 180kN. Simultaneously, based on an established database of bending roll force, strip shape, and surface roughness correlations, combined with real-time strip surface roughness measurements, the mill ensures that the bending roll force adjustment does not adversely affect the strip's surface roughness. During this rolling process, the strip's surface roughness remained within the target range even after the bending roll force adjustment.

[0023] Tension adjustment: Based on the strip specifications and rolling process requirements, the initial tension is set at 80kN on the uncoiler and coiler. During the rolling process, the strip tension is monitored in real time using a tension sensor. When the strip deviates slightly, causing tension fluctuations, the motor speed of the uncoiler and coiler is adjusted to keep the strip tension within the range of 80kN±5kN. By optimizing the tension adjustment, the stability of the strip during the rolling process is ensured, which plays a positive role in controlling the surface roughness of the strip.

[0024] Rolling speed optimization: Based on the strip material, roll wear, and other parameters, the initial rolling speed was determined to be 100 m / min. During the rolling process, the strip surface quality was monitored in real time. When slight uneven roughness was found on the strip surface, the rolling speed was reduced to 90 m / min, and the change in surface quality was observed. After a period of operation, the uneven surface roughness of the strip was improved. At the same time, based on the coordinated control model of rolling speed and other parameters, the rolling force, rolling oil parameters, etc. were synchronously fine-tuned to ensure the stability of the entire rolling process and that the strip surface roughness met the requirements. After the parameter optimization adjustment of this embodiment, the surface roughness of the produced strip was stabilized between Ra0.72-0.78 μm, which fully met the surface roughness requirements of aluminum strip for electronic equipment casings.

[0025] Example 2 - Rolling of aluminum strip for food packaging: Rolling force and time calibration: For aluminum strip for food packaging with a thickness of 0.2 mm and a width of 800 mm, multiple rolling tests were conducted under standard rolling conditions to establish a rolling force-time-roughness mapping model. In actual production, the target strip surface roughness requirement is Ra 0.5-0.6 μm. Based on the model, the rolling force setting is 800 kN, and the estimated rolling time is 90 seconds. During the rolling process, the rolling force and time are strictly controlled according to the set values ​​to ensure accuracy.

[0026] Reduction Optimization: Finite element simulations determined the appropriate reduction to be 0.06mm. During actual rolling, the reduction is precisely controlled and fine-tuned based on real-time strip thickness monitoring. For example, if strip thickness fluctuates, the reduction is adjusted promptly to maintain a thickness tolerance within ±0.008mm, while also taking into account the impact on strip surface roughness.

[0027] Bending roll adjustment: During the rolling process, the bending roll force is adjusted according to the changes in the strip shape. When edge waves appear in the strip, the bending roll force is appropriately reduced from the initial 120kN to 100kN. By referring to the bending roll force-plate shape-surface roughness correlation database, it is ensured that the bending roll force adjustment will not cause the strip surface roughness to deteriorate.

[0028] Tension adjustment: Set the initial tension to 60kN, and use the tension sensor to monitor and adjust it in real time during the rolling process to ensure that the tension fluctuation range is within ±4kN. Through reasonable tension adjustment, the flatness of the strip during the rolling process is improved, which helps to control the surface roughness.

[0029] Rolling speed optimization: The initial rolling speed is set at 80m / min. During the rolling process, if any abnormalities are found in the strip surface quality, such as roughness exceeding the target range, the rolling speed is adjusted according to the actual situation and coordinated with other parameters for optimization. After a series of parameter optimization adjustments, the surface roughness of the aluminum strip produced for food packaging is stabilized between Ra0.53-0.58μm, meeting the surface roughness requirements of aluminum strip for food packaging.

[0030] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to preferred embodiments, ordinary technicians in the field should understand that the specific implementation methods of the present invention can still be modified or some technical features can be replaced by equivalents without departing from the spirit of the technical solutions of the present invention. They should all be included in the scope of the technical solutions claimed for protection by the present invention.

Claims

1. A method for controlling the rolling surface roughness of laser-textured work rolls of a four-roll aluminum cold rolling mill, characterized in that: Step S1: before production, rolling tests are conducted on aluminum strips and aluminum strip rollers of different specifications to establish a rolling force-time-roughness mapping relationship model; Step S2: Optimizing the rolling reduction of the aluminum strip using finite element simulation, and dynamically adjusting it in combination with real-time thickness monitoring; Step S3: adjusting the bending roll force according to the shape change of the aluminum strip and the associated database; maintaining stable tension through the tension sensor; optimizing the rolling speed in combination with the material and equipment performance; Step S4: Through real-time monitoring of various parameters and collaborative control model, ensure that the surface roughness of the aluminum strip is stable and meets the predetermined requirements.

2. The method for controlling the rolling surface roughness of the laser-textured work rolls of a four-high aluminum cold rolling mill according to claim 1, characterized in that: In step 1, before production, for aluminum strips and aluminum strip rollers of different specifications, the rolling force, time and surface roughness data are recorded through multiple rolling tests to construct a mapping relationship model; in actual production, the model is queried according to the target roughness, the initial rolling force and time parameters are set, and real-time monitoring is carried out through pressure sensors and timers. When the rolling force fluctuation exceeds ±50kN, the hydraulic system of the aluminum strip roller is automatically adjusted to ensure that the parameters are stable within the set range.

3. The method for controlling the rolling surface roughness of the laser-textured work rolls of a four-high aluminum cold rolling mill according to claim 1, characterized in that: Step 2 is to use finite element simulation software to analyze the effects of different reductions on deformation, stress distribution and roughness based on the material, initial thickness and target thickness of the aluminum strip, so as to select the optimal reduction for rolling the aluminum strip. During the rolling process, the reduction device is used for precise control and real-time monitoring of the strip thickness. When the deviation exceeds ±0.01mm, the reduction is dynamically fine-tuned. At the same time, the chain effect on rolling force and speed is comprehensively considered for coordinated optimization.

4. The method for controlling the rolling surface roughness of the laser-textured work rolls of a four-high aluminum cold rolling mill according to claim 1, characterized in that: Step 3: Monitor the force value in real time through the bending roll force sensor, adjust the bending roll force based on the change in the aluminum strip shape, and establish a bending roll force-shape-roughness correlation database. According to the real-time measurement results of the aluminum strip surface quality, match the optimal adjustment strategy from the database to ensure that the shape is improved without affecting the roughness.

5. The method for controlling the rolling surface roughness of the laser-textured work rolls of a four-high aluminum cold rolling mill according to claim 1, characterized in that: Step 3: Set the initial tension according to the aluminum strip specifications. Use the tension sensors of the uncoiler and coiler to monitor in real time. When deviation occurs and causes tension fluctuations, adjust the motor speed to maintain the tension within the range of 80kN±5kN. That is, by optimizing the tension, the flatness of the strip and the risk of tensile deformation are balanced to avoid abnormal roughness caused by unstable tension.

6. The method for controlling the rolling surface roughness of the laser-textured work rolls of a four-high aluminum cold rolling mill according to claim 1, characterized in that: Step 3: Determine the initial rolling speed based on the material, roll wear, and equipment performance, monitor the surface quality of the aluminum strip in real time, and dynamically adjust the rolling speed when uneven roughness occurs.

7. The method for controlling the rolling surface roughness of the laser-textured work rolls of a four-high aluminum cold rolling mill according to claim 1, characterized in that: In step 4, the rolling force, reduction, bending roll force, tension, and speed parameters are monitored in real time and dynamically adjusted through the established parameter association models and database. When a certain parameter fluctuates, the system automatically triggers the collaborative optimization of the associated parameters, quickly adapting to production changes caused by material differences and equipment fluctuations, so as to achieve precise control of surface roughness throughout the entire process.