1296 KSME International Journa4 Vos 16 No. 10, pp.

1296--1302, 2002

Mathematical Model for Cold Rolling and Temper Rolling Process

of Thin Steel Strip
W o n - H o Lee*
Instrumentation & Control Research Group, Technical Research Laboratories,
POSCO, Kyungbuk 790-785, Korea

A mathematical model for cold rolling and temper rolling process of thin steel strip has been
developed using the influence function method. By solving the equations describing roll gap
phenomena in a unique procedure and considering more influence factors, the model offers
significant improvements in accuracy, robustness and generality of the solution for the thin strip
cold and temper rolling conditions. The relationship between the shape of the roll profile and
the roll force is also discussed, Calculation results show that any change increasing the roll force
may result in or enlarge the central flat region in the deformation zone. Applied to the temper
rolling process, the model can well predict not only the rolling load but also the large forward
slip. Therefore, the measured forward slip, together with the measured roll force, was used to
calibrate the model. The model was installed in the setup computer of a temper rolling mill to
make parallel setup calculations. The calculation results show good agreement with the
measured data and the validity and precision of the model are proven.

Key W o r d s : S t e e l Cold Rolling, Mathematical Model, Roll Force

function method was achieved by Fleck et al.

I. Introduction (1992). Through assuming that there is a region
of roll flattening where the roll surface is flat
Severe cases of strip roiling, such as thin strip and parallel, they solved the non-convergence
cold rolling and temper rolling etc., cause well problems. In the flat region, no further reduction
known problems with simplified classic circular takes place and the shear or frictional stresses at
arc models, They may have convergence difficult- the roll/strip interface remain at values below
ies or bad sensitivity to process parameters. In that predicted by the Coulomb friction law.
order to solve these problems, some researchers Therefore, the roll pressure in this region can be
have attempted to develop more realistic models obtained by inverting the roll profile to roll
by the use of influence functions describing the pressure relationship defined by the roll deforma-
roll deformation (Jortner et al., 1960 ; Grimble et tion influence function.
al., 1976). These models gave some prediction This model has provided useful reference res-
improvement, but they failed to converge for ults, however it has several shortcomings :
thinner or harder materials as ever. (I) The strip elastic deformation zones at the
A major development in modeling of the thin entry and exit were neglected, which results in
strip and foil rolling process with the influence an underestimation of the load. Because of the
'elastic plug'(Zhu. 1984) effect, the predicted
" E-mall : [email protected] load by this model may be much lower than the
TEL: -r-82-54-220-fi315;FAX: -r-82-54-220-69t4 actual one. Besides, the model could not be used
Instrumentation & Control Research Group, Technical
Research Laboratories. POSCO, Kyungbuk 790-785, in light reduction rolling process in which there
Korea. (Manu.~cript Received December 5, 2001; are relatively large entry and exit elastic zones.
Revised June 25, 2002) (2) The pressure profile iterative loop was

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 Mathematical Model for Cold Rolh'ng and Temper Rolling Process o f Thin Steel Strip 120a7

taken as the basic iterative loop. The boundaries

of different zones are determined with an extra 2. Main Equations
iterative loop. Under some circumstances, it is
very difficult to determine the boundaries of dif- A geometric sketch of the deformation zones is
ferent zones(Yuen et al., 1996) because the shown in Fig. 1. The geometric parameters are
iterative processes to determine the boundaries defined with a polar coordinates system.
would diverge or not converge to unique values. The roll-gap model is based on two
(3) The solution procedure was divided into relationships which enable a gauge profile to be
three regimes, namely, Regime I (with no central calculated from a known pressure profile and
flat zone'), Regime II (with a small central flat conversely a pressure profile to be calculated from
zone and one pressure peak) and Regime Ill a gauge profile.
(with a large central flat zone and two pressure The elastic deformation of the work roll is
peaks). For the different regimes there are differ- related to the roll pressure via the linear integral
ent algorithms. Before using the model to calcu- equation.
late a certain rolling case, we have to decide
which regime the certain rolling case belongs a(O) = U(O-t)p(t)dt+R (1)
to. where a(O~ : work roll radius at point 0 ;
Although the boundaries between the diffe- R : undeformed radius of work
rent regimes were given through multi-variable
roll ;
regression analysis in the foil rolling case(Fleck
b(t) : pressure profile.
et al., 1992), it can not be applied to other ca-
U(O-t) : Jortner's influence function
S~S.
Lg, 103,
Several applications of Fleck's work were fol-
lowed by Domanti et al. (1994), Dixon et al.
(1995), Gratacos et al. (1994), Montmitonnet et
al. (1993), Haeseling et al. (1998), and Liu et al. 9 ,
.. ., . . . ~
r -.|
,il+~i~-I \ -L
,ll-~(8-t!!T ] ,
- i-~-zr, sm ~'-t/tin .--:~~7-.. J-t~ , ~ +
L 9 SU'I 0-~ ! i ~j] /~-.+~ ;.+
(2001).
Some improvements were made, but the above (2)
mentioned problems remained unsolved.
In this paper, the aforementioned shortcomings Roll c a n t e r a n d ~ 0
are eliminated. The strip elastic deformation at o d g l n of p o l a r ~ c-----
the entry and is was taken into consideration. The
roll profile iterative loop is taken as the basic
loop, so that the boundaries of different zones can
be directly determined according to the roll pro-
file. The extra boundary determination iterative
loop is eliminated, and it is relatively easy to 0
determine the boundaries of the different zones.
Besides, which regime the rolling case belongs to
h2
can also be directly determined by observing the
shape of the roll profile. Therefore, it would not
be necessary to determine the regimes and choose
the calculation procedure before hand.
After calibration using the production data, the
newly developed model is applied to the actual Entry a['ast~c z o n e Exit e l a s t i c z o n a
temper roiling process and the validity and preci- ]Fig, ] Sketch of the deformation zones in the roll
sion of the model are also proven. gap
Copyright (C) 2003 NuriMedia Co., Ltd.
 1298 Won- Ho Lee

where A ~ i segmental angle;

T = J f ' a 2 ~ O ) [ r ( 0 ) +p(O)tan~]dt~ (8)
The gauge profile is determined by the de-
where ~ " a n g l e between undeformed roll and
formed roll radius according to the equation.
horizontal axis.
h(8) - - R g - 2 a ( 8 ) c o s ( O - f 3 o ) (3)
At the same time, the forward slip, f , can also
where h(O) : gauge profile ; be approximately calculated with the following
Rs : d i s t a n c e between centers of the formula :
work rolls ;
f = h~i'h2- I (9)
(~o ~ angle measured to the line of work
roll centers. where h,, strip gauge at a flat region or a neutral
point ;
The pressure profile is related to the gauge
hz strip gauge at the exit side.
profile via differential equations. In the entry and
exit elastic regions it is :
3. Calculation Procedure and Analysis
dp 2a( #Pv-~l)(l-2v)tan~ , (2h-h~)tan~E] c , of N e w Model

and in the plastic regions: The main flow chart of the calculation proce-
dure is shown in Fig. 2. The iterative calculation
ap_=- dv
-2ha--( u p - "vl tan~) + d~-- procedure is introduced to solve the equations
da (5)
describing the r o l l - d e f o r m a t i o n and the strip-
where v : Poisson's r a t i o ; stress distribution. No matter which regimes the
E : Young's modulus of elasticity.
h~ : unstrained gauge in a elastic region ;
/~ ~ angle between deformed roll and hori-
Assume
zontal ;
y : yield stress;
,u : friction coefficient between rolls and
the strip ;
In the central flat region, the discrete pressure of D~fferentZotms ]
profile can be obtained by solving the following , , '~ ,

linear equation system (all parameters are ex-

pressed in discrete form):

~, i "', R,-h, R,-h,

-
(
,,
: ~, t r
-
r Molly Rs

where j l : the first node in the flattened region ;

j2 : the final node in the flattened region ; ~es
e : the node at entry p l a n e : ~ _ No
d : the node at exit plane.
Once the pressure and gauge profiles are deter- . ~Y~
mined, the roll force, P , and torque, T , can be
calculated through integration of the pressure and
I
friction force distribution :
Outout Ras~

Fig. 2 The calculation procedure of new model

Copyright (C) 2003 NuriMedia Co., Ltd.
 Mathematical Mode~for Cold Rolling and Temper Rolling Process oJ" Thin Steel Strip 1299

rolling conditions belong to, the same calculation from one peak(regime 1I) to two peaks(regime
procedure can be used. That is one of the most 111} , and the length of the flat region and the roll
important advantages in the present model. force also increases more than two times. It rev-
Before applying the present model to actual eals that the same calculation procedure can be
temper rolling process, the reliability and conver- used regardless of deformation regimes in the
gence of calculation result were checked with present model.
various roiling conditions. Here, some typical Figure 4 shows the effect of the friction co-
calculated results are introduced. efficient u p o n the gauge and pressure profile un-
Figure 3 is an example of foil, which is ultra der temper rolling conditions. It can be seen that
thin material, cold rolling process calculation. not only the pressure profile but also the gauge
Three reduction rates were used in the calculation profile is greatly influenced by the friction co-
Though very thin entry thickness was used, efficient. At low friction conditions, the contact
there was no convergence problem, in this model. arc between the roll and the strip is nearly circu-
It can be seen that as the reduction increases lar, but at high friction conditions, a flat region
from 5096o to 70% the pressure profile changes appears in the central part of the contact arc.

rl~ie~ pr~
Oil

U. l l l t l

t In
_ _
)
-..;..!_<._._."
~,--"-~_ (c)
-.\

Iil,li 1Ill
-'~') :' J
IJl

l~l c i n l i l
910=1

O ' -
li 9 41 4 tJ 9 Illl I 11 1 iJ
(deO)
Fig. 3 Thickness and pressure profile of foil cold rolling
R'---89 ram, friction coefficiem-=0.03, ay---230 Mpa, entry thickness=0.03 ram, E=230 Gpa.
(a) reduction----30% (b) reduction=50% (c) reduction=70%

Thict~m~e ~ P w ~r~lle

t..
!///
._
t\ ~. ca)..'-3,~ t / i;" c.) ,,>, \\
~ '~+ ~". ," 7c).,~:

(dig) Thlt= (deg)

Fig. 4 Thickness and pressure profile under different friction coefficients
R----205 ram, o3,=196 Mpa, entry thickness=0.505 ram, reduction=0.46~ rolling speed----37 re/rain,
entry tension"---2496 kg, exit tension=3616 kg, width= 1073 ram,
(a) #=0.12. (b) v=O.15, (e) ,u=O.18, (d) ,u=0.21
Copyright (C) 2003 NuriMedia Co., Ltd.
 1300 Won-- lto Lee

Yh~la~m. ~
D.
,"'.i
; i,~ / \,
,'~,

|.IDI[

~F
,,'.//
.::,t ',,\'~:.
U.6
:,.//
41~1s

41,r 4.1f 9 11.2

I !i
E.~
.

I1,1
. . .

B~
Them (aog)
Fig. 5 Thickness and pressure profile under different yield stress
R=205 ram, entry thickness=0.505 mm, reduction=0.469/~ width = 1073 ram, rolling spee,d=37 m/min,
entry tension-=2496 kg, exit tension=3616 kg, ,u=0.12
(a) o'y=210 MPa, (b) 03,--=240MPa (c) o3,=270 MPa, (d) 0"y---300Mpa

Similar situation can also be seen when we

change the yield stress of the strip. As shown in
Fig. 5, the contact arc changes its shape from
nearly circular to non-circular, and a central flat
|~ _~
region finally appears, as the yield stress incre- ~F
ases. Besides, the elastic recover zone is also
greatly influenced by the yield stress.
Through the analysis of rolling phenomena, it
was confirmed that the new model has a calcula-
tion stability and can give physically reasonable
result for wide range of temper rolling condi- .... lr M~I
tions.

4. Model Calibration and Application

Result
'1
In otder to use the theoretical model as a setup
model in the elongation control system of a tem-
per rolling mill in POSCO, the model was cali-
brated against the production data collected from
the same mill. The ti'iction coefficient, /z, and the
constrained yield stress, K, were taken as the
calibration factors. Because the roll force, P, and Fig. 6 Calculation of constrained yield stress and
the forward slip, f , can be measured in the tem- friction coefficients
per roiling mill, and they can also be calculated
hy the theoretical model, we used these two we got two coupled equations. Solving the co-
measured data to determine the calibration factors upled equations with the iterative method, we
K a n d / ~ . Equating the measured roll force P= and obtained the constrained yield stress, K, and the
forward slip f= with their calculation formula, friction coefficient ~ for each coil.
which were derived from the theoretical model, Because present model can well predict the
Copyright (C) 2003 NuriMedia Co., Ltd.
 Mathematical Model for Cold Rolling and Temper Rolling Proces~ of Thin Steel Strip 1301

'fable ! The values of the calibration factors for

each group 41,
.l~ 500 +
Steel group
i Constrained yield
i stress (N,/mm 2)
Friction
coefficient.
,oo
CICS ~ 271.3 0.1275
CCCS ! 280.1 0. t262
CHR35R ] 201.9 0.1373 I

- - 4
CH40R ] 237.8 0.1200 8
CDCS 168.3 0.1235
0 2O0 4OO 600
CNCS ' 163.9 0.1251
I I- rne~um rol f~'co(ton)
CECS ~ 155,4 0.277
Fig. 7 Roll three measured and predicted by the
CVEI ] 178.5 0.1141
present model
Mn60 276.7 0.1251
CH35E i 160.9 0.1256 .el.- . 6 O O
CT37 255.5 0.1527 0
.~500
CC8H ~ 313.9 0.1214
- -
CH60C .[i 418.6 0.1157 ,2
4o0
..,j.

CX80DP i 421.7 0.1688 2 3OO

2OO
large forward slip in the temper rolling process, loo
we got reasonable results using the above method. 8 o
A flow chart of the calibration calculation is 0 200 400 600
shown in Fig. 6.
After the constrained yield stress and friction measured roll force(ton)
coefficients were calculated for all coils, we divi- Fig. 8 Roll force measured and predicted by the
ded the coils into groups according to the steel regression model
grades and the constrained yield stress. The av-
erage constrained yield stress and average friction the roll threes predicted by the present model
coefficient of each group were used as the final equals 0.8899.
values of the calibration factors for this group. In order to show the prediction accuracy im-
Table 1 shows the values of the calibration factors provement made by the present model, the re-
for each group. gression model, which had been used as the setup
After calibration, the model was installed in the model in the same temper rolling mill before the
plant together with the data acquisition system to present model was developed, was also evaluated
make parallel calculations and comparisons. An with the same data. Figure 8 shows comparison
evaluation sample that consists of the valid data of the measured roll force and the roll force
of 3724 coils is adopted to make the evaluation calculated by the regression setup model.
and comparison. As we can see, the samples in Fig. 8 are more
Figure 7 shows comparison of the measured mattered than those in Fig. 7. The correlation
roll forces and the roll forces calculated by a coefficient between the measured roll force and
present model. It can be seen that the predicted the roll force calculated by the regression setup
roll forces match the measured values well and model is 0.7175. Besides, the average calculated
the model has relatively high prediction accuracy. roll force is lower than that of the measured roll
A statistical analysis shows that the correlation force. This indicates that the regression setup
coefficient between the measured roll forces and model underestimated the roll force in general. By

Copyright (C) 2003 NuriMedia Co., Ltd.

 1302 Won- Ho Lee

comparison, we can see that the present theo- Domanti, S. A., Edwards, W. J., Thomas, P.J.
retical model is much more accurate than the and Chefneux, l . L . , 1994, "Application of Foil
regression setup model. From a comparison with Rolling Models to Thin Steel Strip and Tem-
the measured data and comparison with the old per Rolling," Proc. 6th International Rolling
setup model, the validity and precision of the Conference, Duesseldorf, Germany, June 20-22,
present model are proven. pp. 422 ~429.
Fleck, N. A., Johnson, K, L., Meat, M. E. and
5. Conclusions Zhang, L. C., 1992, "Cold Rolling of Foil," Proc.
Inst. Mech. Eng., Part B : J. Eng. Man., Vol. 206,
A new mathematical model for the thin strip pp. 119--131.
cold and temper rolling process has been dev- Gratacos, P. and Onno, F., 1994, "Elastoplastic
eloped by modification of the influence function Models for Cold Rolling, Application to Tem-
method. The main differences of present model per Rolling," Proc. 6 th International Rolling
against to basic influence function method are to Conference, Duesseldorf, Germany, June 20-22,
be summarized as follows : pp. 441--445.
(I) The strip elastic deformation at the entry Grimble, M. J., 1976, "A Roll Force Model for
and exit was taken into consideration. Tinplate Rolling," GECJ. o f Science & Tech.,
(2) The roll profile iterative loop was taken as Vol. 43, No. 1, pp. 3 ~ 12.
the basic loop so that the boundaries of different Haeseling, G., Kasmer, S., Kramer, A. and
zones can be directly determined according to the Hartung, H.G., 1998, "New Foil Rolling Theo-
roll profile. ries and Their Importance for Industrial Prac-
(3) The new calculation procedure was intro- tice," M P T International, No. 6, pp. 86--91.
duced to apply the new model to various rolling Jortner, D., Osterle, J. F. and Zorowski, C. F.,
conditions. Therefore, it would not be necessary 1960, "An Analysis of Cold Strip Rolling," lnt. J.
to determine the regimes and choose the calcula- Mech. Sci., Vol. 2, pp. 179--194.
tion procedure before hand. Liu, Y. and Lee, W., 2001, "Application of the
By solving the equations describing the roll gap Preliminary. Displacement Principle to the Tem-
phenomena in a unique procedure, the new model per Rolling Model," K S M E International Jour-
offered significant improvement in the accuracy, nal, Vot. 15, No. 2, pp. 225~231.
robustness and generality of the solution for thin Montmitonnet, P., Massoni, E., Vacance, M.,
strip cold and temper rolling conditions. Sola, G. and Gratacos, P., 1993, "Modeling for
The model was installed in the process com- Geometrical Control in Cold and Hot Rolling,"
puter of an actual temper rolling mill to make lronmaking and Steelmaking, Vol. 20, No. 4,
setup calculations. The calculation results showed pp. 254--260.
good agreement with the measured data and the Yuen, W. Y. D., Nguyen, D. N. and Matthews,
validity and precision of the model were proven. D. L. 1996, "Mathematical Modeling of the Tem-
per Rolling Processes," 3 7 T H M W S P CONF.
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