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FE modeling of the cooling and tempering steps of bimetallic rolling mill rolls

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Abstract

Numerical simulations enable the analysis of the stress and strain histories of bimetallic rolling mill rolls. The history of rolling mill rolls is simulated by thermo-mechanical metallurgical finite element code while considering two steps: post-casting cooling and subsequent tempering heat treatment. The model requires a notably large set of material parameters. For different phases and temperatures, Young modulus, yield limit and tangent plastic modulus are determined through compression tests. Rupture stresses and strains are obtained by tensile tests. Thermo-physical parameters are measured by such experimental methods as dilatometry, DSC (Differential Scanning Calorimetry) and Laser Flash methods. Such parameters as the transformation plasticity coefficients for the ferrite, pearlite and martensite phases are identified through an inverse method. From the simulation results, the profile of the stresses evolution at different critical times is presented. An analysis of the potential damage is proposed by comparing the predicted axial stress with rupture stresses. The perspective of the Ghosh and McClintock damage criteria is also investigated.

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Acknowledgments

The authors acknowledge to the National commission for scientific and technological research (Conicyt) Chile, for financial help. Interuniversity Attraction Poles Program-Belgian State-Belgian Science Policy P7 INTEMATE is thanked for its support. As research Director of FRS-FNRS, AM Habraken thanks this organization for its financial support.

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Authors and Affiliations

  1. Department ArGEnCo, Division MS2F, University of Liège, Quartier Polytech 1, Allée de la découverte 9, Bât B52, 4000, Liège, Belgium

    Ingrid Neira Torres, Gaëtan Gilles & Anne Marie Habraken

  2. Department of Materials Engineering, University of Concepción, Edmundo Larenas 270, Concepción, Chile

    Ingrid Neira Torres

  3. Department AME, Division MMS, University of Liège, Quartier Polytech 1, Allée de la découverte 9, Bât B52, 4000, Liège, Belgium

    Jérôme Tchoufang Tchuindjang & Jacqueline Lecomte-Beckers

  4. Department of Mechanical Engineering, University of Concepción, Edmundo Larenas 219, Concepción, Chile

    Paulo Flores

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  1. Ingrid Neira Torres
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  5. Jacqueline Lecomte-Beckers
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Correspondence to Ingrid Neira Torres.

Appendices

Appendix A: Input parameters

Most part of the required parameters for numerical simulations have been provided by tables or figures in this work (Young moduli, yield limits, tangent plastic moduli for interesting phases and temperatures, fracture strains, thermo-physical properties, transformation plasticity coefficient). Parameters such as TTT diagrams, Coefficient of Thermal Expansion (CTE) and transformation strains for both SGI and HCS materials, have been given in previous works [48, 49]. However, in order to provide a complete set of data, these parameters are here reminded.

TTT diagrams

Within the numerical simulations, the phase transformation model is based on TTT diagrams. For SGI and HCS grades, TTT diagrams of Fig. 20 were obtained using inverse method through FE code using a CCT diagram as input data.

Fig. 20
figure 20

TTT diagrams (a) SGI grade (b) HCS grade

Full size image

Coefficient of Thermal Expansion (CTE)

Dilatometry tests were performed using a dilatometer NETZSCH - 402C. Each tested sample was reheated at 3 °C/min up to 1025 °C with a holding time of 1 h and then cooled to room temperature at 3 °C/min. From the experimental curves, the incremental CTE for non-linear FE code αFE for each case is computed (see the result in Fig. 21). These curves define the parameters used within cooling and heating simulations.

Fig. 21
figure 21

Coefficient of Thermal Expansion (a) SGI material (b) HCS material

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Transformation strain

The inverse method was applied to identify the correct value of austenite transformation strains to ferrite and pearlite phases ε tr Fe − Pe for SGI material and to martensite phase ε tr Ma for HCS material. The value of ε tr k was modified several times to accurately predict peaks appearing in the experimental dilatometry curves for each material during the cooling sequence. Displacements computed must recover the variation of length experimentally measured. For SGI material, the same value of transformation strain was considered for ferritic and pearlitic transformation. For HCS material, only martensitic transformation case was studied. Values of transformation strains obtained by inverse modelling are given in Table 7.

Table 7 Transformation strain values
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Neira Torres, I., Gilles, G., Tchoufang Tchuindjang, J. et al. FE modeling of the cooling and tempering steps of bimetallic rolling mill rolls. Int J Mater Form 10, 287–305 (2017). https://doi.org/10.1007/s12289-015-1277-0

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