Work Roll Contour Design for Strip Rolling Profile Control
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Solution Overview
Problem
Wide strip rolling often results in undesirable profile shapes and flatness defects due to backup or intermediate roll setbacks, leading to non-parabolic roll gap profiles and impaired dimensional accuracy, which existing solutions fail to adequately address.
Innovation Solution
A method involving the calculation of a compensation cut for the work roll by subtracting the desired rolling stock contour from the roll gap profile, multiplied by a damping factor, to be applied to the work roll, which can be superimposed on existing profiling such as CVC profiling, to compensate for the setback effects and maintain high-quality rolling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If backup or intermediate rolls have a setback in their axial end regions, then the rolling mill can handle wide strip rolling, but non-parabolic roll gap profiles and bulging occur leading to poor product quality
Solution Approach 1:
The work roll is given a non-uniform contour with different radii in different axial regions. The contour includes a first radius in the central region and a second radius in the end regions, creating local variations in the roll surface geometry to compensate for the setback effect and achieve uniform roll gap profile across the width.
Solution Approach 2:
The non-uniform contour is pre-formed on the work roll before the rolling operation. This preliminary shaping of the work roll contour ensures that when the rolls engage, the roll gap profile is automatically compensated for the setback, eliminating the need for real-time adjustment during rolling.
2Length of moving object
If work rolls are extended beyond the backup roll edges, then wide strips can be rolled, but work roll bending increases causing bead formation and flatness defects
Solution Approach 1:
The work roll contour is differentiated into central and end regions with different radii. The end regions have a smaller second radius compared to the central first radius, which locally reduces the lever arm for bending moments in the extended regions, thereby reducing bead formation and flatness defects.
Solution Approach 2:
The work roll is given a curved contour rather than a straight cylindrical shape. The varying radius creates a curved surface that, when combined with the setback configuration, produces a more uniform roll gap profile across the width of the strip, compensating for the extended length effect.
3Manufacturing precision
If roll grindings are applied to influence the roll gap profile, then profile control is improved, but the complexity of work roll manufacturing increases
Solution Approach 1:
The non-uniform contour is incorporated into the work roll design from the beginning, allowing the roll to be manufactured with the correct geometry in one step. This preliminary design approach eliminates the need for subsequent grinding operations to achieve profile control, simplifying the manufacturing process.
Solution Approach 2:
The profile control function is merged into the basic geometry of the work roll itself. The non-uniform contour serves both as the structural form of the roll and as the profile control mechanism, combining what would traditionally be separate functions into a single integrated design.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method effectively compensates for the bending behavior of the work roll in the setback region, ensuring consistent high-quality rolling across the entire displacement range, reducing bulging and maintaining desired shape without disrupting narrower dimensions.
Implementation Method 1
The work roll bends back in these areas, so that a non-parabolic profile shape can occur in the roll gap as a result
Data Source
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AI summary
The invention relates to a method for providing at least one work roll (1, 2) for rolling strip-shaped rolling stock (3), wherein the work roll (1, 2) is provided to interact with a second roll (4, 5), particularly with an intermediate or backup roller and be supported by said second roll, wherein the second roll (4, 5) has a background area (6) in the axial end regions thereof. In order to improve the quality of a rolled strip, the method according to the invention provides the following steps: a) calculating the roll nip profile resulting between two interacting work rolls (1, 2), wherein a defined width of the rolling stock (3) is assumed, which extends at least partially into the region of the background area (6) of the second roll (4, 5); b) defining a desired rolling stock contour that is to be created by the rolling process when passing the work rolls (1, 2); c) calculating a compensation cut for the work roll (1, 2) by subtracting the defined rolling stock contour according to step b) from the roll nip profile according to step a) and multiplying the calculated difference with a damping factor (K); d) at least partially applying the compensation cut calculated according to step c) to at least one work roll (1, 2).