docKinematic and Structural Simulation of Rolling Mill
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Kinematic and Structural Simulation of Rolling Mill
wings of invention Kinematic and Structural Simulation of Rolling Mill Assemblies with Pro/MECHANICA Maik Berger SMS Demag AG 1 M. Berger | SMS Demag AG | Kinematic and Structural Simulation of Rolling Mill Assemblies © Pro-D OHG Agenda wings of invention 1. CSP – Technology by SMS Demag AG 2. Semi-Endless Rolling 3. Flying Shear - Kinematic Model - Pro/E – Design - Simulation with Pro/Mechanica 4. Coiler - Arrangement and Animation - Stress Calculation at the Centrifugal Force Clamp 5. Summary 2 M. Berger | SMS Demag AG | Kinematic and Structural Simulation of Rolling Mill Assemblies © Pro-D OHG Overview of our Process Routes wings of invention CSP - Plant 3 M. Berger | SMS Demag AG | Kinematic and Structural Simulation of Rolling Mill Assemblies © Pro-D OHG wings of invention CSP – Plant Process Route (Compact Strip Production) Years of experience – 25 CSP plants worldwide All in all 39 CSP strands and 139 mill stands 4 M. Berger | SMS Demag AG | Kinematic and Structural Simulation of Rolling Mill Assemblies DOWN COILER COOLING LINE F7 CSP MILL F1 EMERGENCY SHEAR SWIVEL FERRY FURNACE PENDULUM SHEAR TUNDISH / CASTER LADLE TURRET Production capacity more as 50 million t © Pro-D OHG Characteristic of Semi-Endless-Rolling wings of invention Subdividing of hot strip after the caster („Jumbo-Slab“) Continuously rolling with end rolling speed up to 20 m/s Dividing the hot strip into coils by using a Flying Shear Use a switch to guiding the strip head 5 M. Berger | SMS Demag AG | Kinematic and Structural Simulation of Rolling Mill Assemblies © Pro-D OHG Layout of the Finishing Equipment wings of invention Shear Shear Switch Switch 1.1.Coiler Coiler 2.2.Coiler Coiler ANIMATION ANIMATION 6 M. Berger | SMS Demag AG | Kinematic and Structural Simulation of Rolling Mill Assemblies © Pro-D OHG Flying Shear – Function wings of invention Subdividing of semi-endless rolled hot strip in front of coiler at rolling speed Dividing into coils with required coil weights No influence of production process due to cutting procedure Save transport of strip head end through the shear to coiler Save mechanical principle 7 M. Berger | SMS Demag AG | Kinematic and Structural Simulation of Rolling Mill Assemblies © Pro-D OHG 8 UPPER KNIFE DRUM LOWER KNIFE DRUM M. Berger | SMS Demag AG | Kinematic and Structural Simulation of Rolling Mill Assemblies GEAR MOTOR GEAR MOTOR LOWER KNIFE DRUM Start- Brake-Gear Drum Gap Adjustment Start- Brake-Gear UPPER KNIFE DRUM Pinion - GearUnit Cut Start - Brake Flying Shear – General Driving Design wings of invention © Pro-D OHG wings of invention Flying Shear – Kinematic „Start – Brake - Kinematic“ y 1 ϕ21 l4 d2(9) d8(9) l2 A B l3 d9(2) ϕ71 l5 ϕ11 1 D d11(10) l7 ϕ91 l6 1 D0 F = 3 . (11 - 1) - 2 . 12 - 5 = 1 9 1 A0 B l3 d9(2) d2(7) ϕ71 ϕ91 x d9(8) l5 ϕ10 1D d10(8) B0 d2(9) ϕ81 d8(9) A d7(2) d10(9,11) l4 l2 x d9(8,10) C ϕ10 1 1 ϕ21 d8(10) d2(7) d7(2) y B0 1 A0 ϕ81 „Cutting Kinematic“ l7 C l6 1 D0 F=1 M. Berger | SMS Demag AG | Kinematic and Structural Simulation of Rolling Mill Assemblies © Pro-D OHG wings of invention Flying Shear – Pro/E Model 17 16 15 1 8 11 2 3 4 18 14 13 9 5 6 10 7 10 M. Berger | SMS Demag AG | Kinematic and Structural Simulation of Rolling Mill Assemblies 12 11 Shear ShearHousing Housing 22 Upper UpperEccentric Eccentric 33 Upper Lever Upper Lever 44 Rocker RockerArm Arm 55 Link Lever Link Lever 66 Lower LowerLever Lever 77 Lower LowerEccentric Eccentric 88 Upper Knife Upper KnifeDrum Drum 99 Upper UpperCompensation CompensationWheel Wheel 10 Lower Compensation Wheel 10 Lower Compensation Wheel 11 11 Lower LowerKnife KnifeDrum Drum 12 12 Motor Motor 13 13 Series SeriesGear Gear 14 14 Universal UniversalJoint JointShaft Shaft 15 Connection Shaft 15 Connection Shaft 16 16 Pinion PinionGear GearUnit Unit 17 17 Knife KnifeGap GapAdjusting AdjustingMotor Motor 18 Tooth Flank Adjusting 18 Tooth Flank AdjustingMotor Motor © Pro-D OHG Simulation with Pro/Mechanica Motion 11 M. Berger | SMS Demag AG | Kinematic and Structural Simulation of Rolling Mill Assemblies wings of invention © Pro-D OHG VERTICAL KNIFE POSITION [mm] Simulation with Pro/Mechanica Motion UPPER KNIFE wings of invention LOWER KNIFE TORQUE [kNm] TIME [mm] Lower Knife Drum Mmax = 146 kNm Series Gear Mmax = 13,74 kNm TIME [mm] 12 M. Berger | SMS Demag AG | Kinematic and Structural Simulation of Rolling Mill Assemblies © Pro-D OHG Tooth Contour Optimization wings of invention Without Tooth Surface Correction (TSC) Tooth Surface Correction Strip Thickness: (0,8 ... 4,0)mm Without TSC 100% Cutting Force 13 0,15° TSC 50% Cutting Force 0,15° TSC 100% Cutting Force M. Berger | SMS Demag AG | Kinematic and Structural Simulation of Rolling Mill Assemblies Cutting Gap: (0,08 ... 0,27) mm © Pro-D OHG Coiler 14 M. Berger | SMS Demag AG | Kinematic and Structural Simulation of Rolling Mill Assemblies wings of invention © Pro-D OHG Coiler – Layout of the Assembly wings of invention Obere Obere Treibrolle Treibrolle Untere Untere Treibrolle Treibrolle Top Top Pinch Pinch Roll Roll Fangeinrichtung Fangeinrichtung Bottom Bottom Pinch Pinch Roll Roll Strip Strip Catcher Catcher Zylinder Zylinder der der Andrückrolle Andrückrolle Wrapper Wrapper Rolls Rolls Cylinder Cylinder 15 Andrückrolle Andrückrolle Bundausfahrwagen Bundausfahrwagen Haspeldorn Haspeldorn Wrapper Wrapper Roll Roll Coil Coil Stripper Stripper Car Car Downcoiler Downcoiler Mandrel Mandrel M. Berger | SMS Demag AG | Kinematic and Structural Simulation of Rolling Mill Assemblies © Pro-D OHG wings of invention Coiler – Drive Train Rotierende Rotierende Ölzuführung Ölzuführung Rotating Rotating Oil Oil feeding Device feeding Device Bogenzahnkupplung Bogenzahnkupplung Gear Gear Coupling Coupling Scheibe Scheibe zur zur Erfassung Erfassung des Spreizhubs des Spreizhubs Disk Disk for for detecting detecting the the expanding stroke expanding stroke Spreizstange Spreizstange Segmente Segmente Spreader Spreader Bar Bar Segments Segments MOTOR 16 Getriebe Getriebe Hydraulikzylinder Hydraulikzylinder Lagergehäuse Lagergehäuse Dornkörper Dornkörper Dornstützlager Dornstützlager Gear Gear Drive Drive Hydraulic Hydraulic Cylinder Cylinder Bearing Bearing Housing Housing for Mandrel for Mandrel Mandrel Mandrel Body Body Outboard Outboard Bearing Bearing M. Berger | SMS Demag AG | Kinematic and Structural Simulation of Rolling Mill Assemblies © Pro-D OHG Coiler – Mandrel Body with Segments Spreizstange / Spreader Bar wings of invention Lasche / Connecting Bar Segmente / Segments Dornkörper / Mandrel Body Schnitt / Section 17 M. Berger | SMS Demag AG | Kinematic and Structural Simulation of Rolling Mill Assemblies © Pro-D OHG wings of invention Segment Calculation without Centrifugal Force Clamp Model with Boundary Conditions: Bearing Condition – Swivel Joint transversal – isotrope material characteristic z – fixed (Edge) FL Connecting Bar (left) xyz - fixed (Point) Centrifugal Force Clamp free Connecting Bar (right) xyz - fixed (Point) x z Centrifugal Force: 18 y vB = 16 m/s² ωH = 42,667 s-1 FL_16 = 100 % vB = 20 m/s² ωH = 53,333 s-1 FL_20 = 156 % M. Berger | SMS Demag AG | Kinematic and Structural Simulation of Rolling Mill Assemblies © Pro-D OHG Segment Calculation without Centrifugal Force Clamp wings of invention Deformation Equivalent stress 19 M. Berger | SMS Demag AG | Kinematic and Structural Simulation of Rolling Mill Assemblies © Pro-D OHG Connecting Bar Calculation wings of invention Stress trajectory (depth direction) Using the FKM Guideline „Calculated Proof of Strength for Machine Components“ (3rd edition 1998 - iron materials) 20 M. Berger | SMS Demag AG | Kinematic and Structural Simulation of Rolling Mill Assemblies © Pro-D OHG Clamping Force Calculation – FE-Model [R] spring rate: [L] c = 100000 N/mm all forces = 0 c calculate the model d displacement – spring connecting points: forces: 55782 N 41887 N 41565 N 44699 N 34044 N 39003 N 35309 N 37779 N 43284 N 46055 N 65708 N 58885 N 90494 N 97467 N wings of invention e messure the displacement for each clamp (spring point) f g h If displacement > limiting value calculate the required clamp forces ITERATION ITERATION i j (optional) Σ 21 M. Berger | SMS Demag AG | Kinematic and Structural Simulation of Rolling Mill Assemblies © Pro-D OHG wings of invention Clamping Force Calculation – Iterative Steps Clamping Forces [N] - Left Side 125000 110000 95000 80000 65000 50000 35000 20000 1 0. Iteration 22 2 3 1. Iteration 4 5 2. Iteration 6 7 3. Iteration M. Berger | SMS Demag AG | Kinematic and Structural Simulation of Rolling Mill Assemblies © Pro-D OHG wings of invention Mandrel Body Calculation [R] [L] Torque: c d e f g h i 23 M. Berger | SMS Demag AG | Kinematic and Structural Simulation of Rolling Mill Assemblies © Pro-D OHG wings of invention Stress Results Segment c d e f g h i Mandrel Body 24 M. Berger | SMS Demag AG | Kinematic and Structural Simulation of Rolling Mill Assemblies © Pro-D OHG Assembly Calculation as Contact Model wings of invention ¼ Symmetry Model 16 Contact Surfaces 25 M. Berger | SMS Demag AG | Kinematic and Structural Simulation of Rolling Mill Assemblies © Pro-D OHG Assembly Calculation as Contact Model wings of invention Total Displacement 26 M. Berger | SMS Demag AG | Kinematic and Structural Simulation of Rolling Mill Assemblies © Pro-D OHG Summary wings of invention • Nowadays 3D-Animation and -Simulation are very important for design, calculation, optimization and presentation of parts, assemblies and complete rolling mills. • Pro/Mechanica has been proved as a very suitable tool for kinematic and structure mechanical simulations of complex assemblies. • The kinematic analysis and optimization of the Flying Shear was based on detailed Pro/E-Model. • For calculations with a lot of design variants it is often useful to generate simplified substitute models. 27 M. Berger | SMS Demag AG | Kinematic and Structural Simulation of Rolling Mill Assemblies © Pro-D OHG wings of invention E-Mail: mber@sms-demag.de 28 M. Berger | SMS Demag AG | Kinematic and Structural Simulation of Rolling Mill Assemblies © Pro-D OHG
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