Data materials for Presentation at the 12th International Rolling Conference
Trieste, Italy, 2022


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Mill Process Calculations – A Design and Optimization Tool for Wire Rod and Bar Mills developed at the University of Duisburg-Essen
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Dr.-Ing. Christian Overhagen <christian.overhagen@uni-due.de>
University of Duisburg-Essen, Germany
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Files in this repository

1) The barmill example
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The barmill has 16 stands and the considered example is a pass design for 20 mm round out of an entry section of 140 mm.

BARMILL_COOLING: the barmill example with cooling section
BARMILL_NO_COOLING: the barmill example without cooling section

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2) The intermediate mill example
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The intermediate mill is taken out of a classical wire rod mill and reduces a nominal 32 mm entry to a nominal 15.5 mm round section, which serves as the entry into a low-reduction finishing block.

The included calculations feature:

IM2_REF:    Calculation with 32.0 mm entry for the reference state and moderate tensions (10% of flow stress)
IM2_31-5:   Calculation with 31.5 mm entry and the same rotational speeds as the REF calculation
IM2_32-5:   Calculation with 32.5 mm entry and the same rotational speeds as the REF calculation
IM2_OPT:    Calculation with 32.5 mm entry and optimized rotational speeds for 10% tension in this case


3) The 170 square to 48 round example
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Calculation example for the pass design from 170 mm square to 48 mm round mentioned in the paper.

First 16 passes: With no tensions and no elastic feedback
Second 15 passes: With 10% tension in the finishing mill (roughing stand without tensions) and elastic feedback.



GENERAL description of the files (all in ASCII format)
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.DAT files contain the metal forming relevant data calculated in a long table:

PsNo			Pass Number  
Std      		Stand Denomination for Pass
DmNom    		Nominal Roll Diameter
DmWrk    		Working Roll Diameter
Gap      		Definition gap of groove
ScrewDown 		Relative screwdown setting
IsGap     		Actual gap including screwdown
Temp         	Mean rolling temperature
A1        		Cross section after the pass
Epsa    		Relative cross-sectional reduction (pass draft)
Sec_H1   		Height of section after the pass
Sec_B1     		Width of section after the pass
A_dis     		Displaced Area
A_reap    		Reappearing Area
fs      		Elongation Efficiency
H0l        		Equivalent entry height (Lendl Height)
H1l        		Equivalent exit height (Lendl height)
Bl    			Lendl Width (Intersection distance)
Ad/Am 			Roll gap shape factor
Af/Af0      	Related neutral angle
CG       		Stand rigidity
Feedb.     		Elastic feedback of stand
dAl        		Cross-Sectional change due to tensions
AS/A       		Related cross-sectional change due to tension
dH        		Absolute height reduction (delta h)
dB       		Absolute width gain (delta b)
dB/dH  			Relation delta b / delta h
Lambda   		Elongation factor = l1/l0
Beta    		Spreading factor = b1/b0
Gamma    		Reduction factor = h1/h0
Phiv     		Equivalent true strain
v0      		Entry speed
v1      		Exit speed
vu     			Circumferential roll speed
Omega    		Roll angular speed
RollRPM			Roll revolutions per minute 		
FwdSlp			Forward Slip
BwdSlp 			Backward Slip
Phipm   		Mean strain rate
Kfm      		Mean flow stress
Kw    			Mean deformation resistance
Kw/Kfm   		Reciprocal deformation efficiency 
rs/r     		Related flattened roll radius
F         		Roll Force
Md        		Torque on both rolls
P     			Power of both rolls
Gr  			Drive group if present
PGroup   		Power of present drive group
LvrArm  		Lever arm factor (compared to Trinks' torque model)
Sigmal0  		Entry tension
Sigmal1  		Exit tension
Spec.F   		Specific Roll Force (per mm width)
Spec.T   		Specific Torque (per mm width)
RadLoss.  		Temperature loss due to radiation heat
FmHeat   		Temperature gain due to forming energy
CndLoss  		Temperature loss due to conduction with the rolls
Balance         Relative temperature balance in the pass

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.GRF files contain the polygonal contours of the entry section, roll groove and exit section in x-y coordinates

For each pass 6 Columns

x-entry		y-entry		x-groove	y-groove	x-exit	y-exit

The first 16 passes are without elastic feedback, the second 16 passes are with elastic stand feedback.

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.PDF files (without _GEOMETRY) contain summary of the data in diagrams including temperature profiles.


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..._GEOMETRY.PDF files contain geometrical output from the GRF-files (could be reproduced from the GRF file).
The displaced and reappearing areas are shaded for a graphical indication of the elongation efficiency.
The first 16 passes are without elastic feedback, the next 16 passes contain the elastic stand feedback.
The "contact" view is always drawn with dashed lines, indicating the first contact of the section and the rolls.


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.TEMP files contain temperature profile data in 5 columns (time, position, tcore, tmean, tsurface) as represented in the .PDF files.


If you have any questions regarding these data examples, please contact me.

Christian Overhagen
<christian.overhagen@uni-due.de>