Transfer behaviors and evolution of surface micromorphology of non-smooth strip in temper rolling process with rough roller
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摘要: 针对平整轧制过程不同用途带钢对表面微观形貌的特殊要求，在批量跟踪电火花毛化轧辊、磨削轧辊和冷轧后带钢表面微观形貌的基础上，建立工作辊与带钢都可考虑真实表面粗糙峰的带钢表面微观形貌轧制转印生成模型，采用工业实验验证了仿真模型的准确性，并据此模型分析轧制前带钢已经具有表面粗糙度分别大于、等于、小于轧辊表面粗糙度时，带钢表面微观形貌的轧制转印行为与遗传演变规律。提出了负转印和转印饱和的概念，定义了两种极限轧制转印状态的描述指标— —负转印最大和转印饱和，研究发现当带钢表面粗糙度小于或等于轧辊表面粗糙度时，存在负转印最大点和转印饱和点；当带钢表面粗糙度大于轧辊表面粗糙度时，负转印最大点和转印饱和点重合。在此基础上，采用负转印最大点与转印饱和点对应的临界板宽轧制力，描述带钢表面微观形貌的遗传及演变规律，并系统仿真分析带钢屈服强度、带钢轧前表面粗糙度、轧辊表面粗糙度等工艺条件参数对于负转印最大点与转印饱和点对应的临界单位板宽轧制力的影响规律，发现随着带钢屈服强度增大和轧辊表面粗糙度增加，该临界单位板宽轧制力均增大；随着带钢表面粗糙度增大，负转印最大点对应的临界单位板宽轧制力增大，但转印饱和点对应的临界单位板宽轧制力却减小。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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图 1 不同加工方式工作辊轧制带钢表面三维微观形貌。（a）电火花加工；（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
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图 2 两种典型带钢表面微观形貌轧制与板宽方向二维轮廓。（a）电火花加工；（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
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图 3 平整轧制过程粗糙工作辊与非光滑带钢轧制转印模型。（a）三维模型；（b）局部放大图
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
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图 4 工作辊与带钢二维平面仿真模型。（a）平面压入几何模型；（b）有限元仿真网格划分
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
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图 5 不同轧制力下带钢表面粗糙度遗传和演变规律
Figure 5. Inheritance and evolution of strip surface roughness under different rolling forces
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图 6 不同单位板宽轧制力下带钢与工作辊的位移场分布。（a）带钢尖峰挤压；（b）轧辊尖峰压入；（c）轧辊凹坑填充；（d）轧制转印饱和
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
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图 7 平整轧制过程带钢表面微观形貌遗传和演变规律示意图
Figure 7. Diagram of the inheritance and evolution of strip surface micromorphology in the process of flat rolling
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图 8 工作辊Ra > 带钢Ra时不同影响因素对负转印最大点对应临界单位板宽轧制力的影响。（a）工作辊表面粗糙度；（b）入口带钢表面粗糙度
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
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图 9 工作辊表面二维轮廓支撑长度率曲线
Figure 9. Support length ratio curve of two-dimensional contour of work roll surface
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图 10 工作辊Ra > 带钢Ra时不同影响因素对轧制转印饱和点对应临界单位板宽轧制力的影响。（a）工作辊表面粗糙度；（b）入口带钢表面粗糙度
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
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图 11 工作辊Ra < 带钢Ra时不同影响因素对转印饱和点对应临界单位板宽轧制力的影响
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
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图 12 工作辊Ra = 带钢Ra时不同轧制力下带钢表面微观形貌的遗传和演变规律
Figure 12. Inheritance and evolution of strip surface morphology under different rolling forces when work roll Ra = strip Ra
表 1 两种典型带钢表面微观形貌轧制与板宽方向二维轮廓粗糙度参数
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 工业实验工况表
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 模型计算带钢表面粗糙度参数与实验实测值对比
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 带钢表面粗糙度遗传和演变规律计算工况
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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