ABOUT

It is well known how much finite element analysis is useful today, especially thanks to the new technology and computer development which have given a boost to FEM in a large number of engineering sector. Traditionally the control of process parameters has been carried on based on operator experience. Indeed, lab tests takes hours or days and this is not in agreement with production time. FE modelling permits to reduce rolling mill setup time but is not for all: use this tool is difficult under a lot of expect and it is necessary to be well experts in the fields to have good results in reasonable time.

However, FE simulation Finite Element modelling is an important technique in the hands of those who wants support to process design and this is where comes the Fastloroll projects.

Fastloroll aim to overcome this limit by developing a fast FE simulation platform which also allows a huge number of simulations of rolling process, in order to improve wider application of FE plant setup optimization system based on material, inclusion and pores models and thus improving the material properties and product tolerances.

The code will be the combination between an automatic pre-processor (whose task is to automatically generate the inputs of calculation core in terms of mesh, material data, geometrical information, contact and boundary conditions) and a customised “user-friendly” interface.

The power of the FastLoRoll project is that it can be used by the plant technologists as well the FE expert: this is possible thanks to the combination between a “user-friendly” interface and simplified FE models. It will also allow reducing computational effort, which is one of the most challenging tasks in finite element analysis.

The core of the new FE code will be implemented considering two different approaches, whose combination of advantages and disadvantages can assure the realization of the new FE platform: 2.5D transient Lagrangian: the most accurate method for computation of large strain –deformation-rotation applied to elasto-plastic problems, and 3D steady state Eulerian, a method widely used because it can help reducing computational effort in presence of numerical simulation of multi-pass long product rolling which requires very long calculation time.

• Reduce the tons of downgraded and scrapped product which as to be put back in the electrical furnace/BOF by increasing the steel plant yield and optimizing rolling mill operating procedures in order to reduce non-conformity in product.
• Gain best quality on the final integrity of product by means of improvement the capability of predicting the effect of inclusions and pores closures of rolled product.
• Industrial rolling trials of developed methods in three different use case applications along the process chain at CMC and ORI MARTIN industrial partners.
• Transfer of FE techniques to the mill technologists by training on the developed code usage.
• Give an added value to the long product steel producers to enhance their capability of understanding how to improve process and product with innovative plant configuration as well to understand how far their current rolling plant layout can reach new product requirements or grades.