Analysis of Alligatoring Behavior During Roll Pressing of DRI

Science Forum Vo /s. 475-479 (2005) pp. 3223-3226
http://www.scientific.net
Trans Tech Publications, Switzerland
Analysis of Alligatoring Behavior During Roll Pressing of DRI
powder with Flat Roller and Indentation-type Roller
S.-H. Joo
1
•
8
,
H.-J. Chang 2 • b' W.H, Bang 2• c. H. N. Han 3 • d and K. H. Oh 4 • e
1
POSCO, Pohang, Gyeongbuk, 790-785 Korea
School of Materials Science and Engineering, Seoul National University, Seoul151-742, Korea.
3
Materials Processing Department, Korea Institute of Machinery and Materials, Changwon,
Kyungnam, 641-010 Korea
8
Shjoo@posco.co.kr, bs98jhj84@snu.ac.kr, cusk2@snu.ac.kr, dhahan@kmail.kimm.re.kr,
8
kyuhwan@snu.ac.kr
A computational model for roll pressing of powder was developed based on an
tlas1topllasti"c finite element method, and was applied to predict the alligatoring behavior at roll nip
powder compacting process. The yield criterion for powder has been implanted for the
IIDUuuum of the roll pressing of Direct Reduced Iron powder with both flat roller and indentation-
roller. Calculated results could well explain the experimental observation that the indentationroller is more useful to hinder in alligatoring.
the roll pressing [ 1] of powder (Fig. 1a), enlarging the thickness of compacted sheet offers more
DCD>mJ.cal efficiency. However over-enlargement of the sheet thickness may give rise to the
"P'"'"'"o phenomenon at the end of roll pressing (Fig. 1b). Alligatoring mechanism based on
stress was proposed by Backofen [2]. In the model, the sheet splitting is caused by a RD
stress, which represents tension in surface and compression in center. In this work, it was
that during roll pressing with flat roll (Fig. 2a), RD stress states are compression in
and tension in center, after exit of the pressing the RD residual stress state is reversed.
may split the compacted powder sheet. Making indentations on the surface of rollers (Fig.
bas been suggested as the solution against the alligatoring problem [3].
Several mathematical models for porous material have been proposed for the numerical approach.
and Prager [4] suggested the generalized Mohr-Coulomb model into three-dimensional
(b) alligotoring
Fig. 2
Finite element mesh of two kinds of roller.
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situations. Park eta/. [5] modified the yield criterion, suggested by Doraivelu ea al. [6], to analyze
the compaction of powder particles.
In this paper, the experimental result on a critical sheet thickness that leads to the alligatoring is
compared with the analysis by the finite element method based on the yield criterion of powder
suggested by Park et al. [5]. We present an interesting conclusion that indentations type roller offers
larger quantity product than flat roller because the indentations increase the critical sheet thickness.
Numerical model
The yield criterion of a porous material can be generalized in a following form
(1)
where J; is second deviatoric stress invariant, and J 1 first stress invariant, R relative density, Rr
tap density, K a strength coefficient, n a strain hardening exponent and Eo an accumulated plastic
strain in incompressible base metal. The parameters m, K and n can be obtained by the best fitting
of the uniaxial compaction data. The equation for uniaxial powder compaction is expressed by [5]
(2)
Experiments
Uniaxial die compaction was used to find out the parameters K, n and m of DRI powder, which
has the circular type shape with rough surface and 2.2 mm average size and was used for the roll
pressing, in Eq. (2). After compaction, the change of the average density of powder compact offered
a pressure-density diagram with increasing the pressure. As shown in Fig. 3. From the experimental
data and Eq. (2), the parameter values in Eq. (1) could be given as K=333.93MPa, n=0.188,
m=2.683 and Rr= 0.45324. These values were used in the FEM analysis for roll pressing of the
powder. The critical thickness of compacted sheet was obtained by checking the alligatoring with
increasing roll gap during roll pressing of the DRI powder. Two kinds of roll pressing with the flat
roller, which has flat surface, and the indentation-type roller, which has indentations on the roller
surface, were carried out. Both rollers have 1000mm diameter and 145mm width. The volume of
indentations is 20 cc. The specific sheet thickness is defined as the ratio of final sheet thickness to
Specificsheet thickness
1.00
2.16
2.66
3.50
4.00
Flat roller
Fine sheet
Fine sheet
Split
-
-
Indentation-type roller
-
Fine Sheet
Fine Sheet
Fine Sheet
Split
Table 1. Pressing results with both kind of roller
Materials Science Forum Vols. 475-479
3225
initially roll gap. While good quality of compacted sheet with specific sheet thickness of 2.16 was
obtained when the flat roller pressed the DRI powder, the compacted sheet with over 2.66 thickness
caused the alligatoring fracture. On the other hand, the indentation-type roll pressing offered the
fine quality of compacted sheet up to 3.5 sheet thickness. Just changing the shape of the flat roller
into the indentation-type roller makes it possible to increase sheet thickness by about 60 percents.
These are illustrated in Table 1.
FEM modeling
The DRI powder was assumed to behave like continuum matter after the critical length between the
rollers as shown in Fig. lb. The critical length was set as (60+roll gap)mm for the flat roll and
(70+roll gap)mm for the indentation-type roll, respectively. Sheet thickness was defined as roll gap
for the flat roll and (roll gap+20)mm for the indentation-type roll, respectively. A minimum length
between two rollers defmed the roll gap. An adaptive mesh technique and a user subroutine
(UMAT) for the yield criterion of Eqn. (1), which are supported in a commercial finite element
code of ABAQUS, were used for FEM simulation. Only half of the calculation system was
analyzed using symmetric boundary condition. The other conditions are detailed elsewhere [7] .
Results and discussion
When the flat roller pressed the DRI powder, the RD stress distributions along the distance through
the rolling direction were shown in Fig 4. The small sheet thickness of 30mm in Fig 4a gives the
100
• experiment
-fltUng
o..--~-
(k-333.13,n-G.118,m• 2.Sil)
(
-100
\
j....
.
\
.... ~\
,'
"
400~~~~~~~~~~~
0
Rolatlvo Den1lty
so
100
150
200
250
Oi1tant thoough rolling dl...:tlon (mm)
300
·100 '--'-.....l.......t..-L..........~L.L...I~--L.-'--'
0
10
100
110
200
210
soo
Diatant through rolling direction (mm)
(b) Sheet thickness = 60mm
(a) Sheet thickness = 30 mm
Fig. 3 Uniaxial compacting results
...
...
- p N. .I n g - -
_100
~
!.
"
0 4'
.....
l ;r
J,l~' f'r
I
.,\..!
IV
........_
'
•,I '-'\"''''
11
~I
'' ~~-Center
- · s~uf•cj
I
I
o,
I
1 ·100
II.,
I , ...
'
'''
('
!
-300 0
10
100
110
200
110
Olatanc• through rolling direction (mm)
(a) Sheet thickness = 601111
Fig. 4
Stress distribution along with rolling direction in flat roll
1.0
110
100
re sslng
0.1
~
'fso
J!:
:·
:IE
~~
i
a:
· 100
-tiO 0
0.7
0.1
10
100
150
200
210
Dlstlnce through rolling direction (mm)
(b) Sheet thickness= 1001111
OA
'
~'•--.. .__
t/ -+- F~t Ron.
-+- Indentation~
X
0.1
Fig. 5 Stress distribution along with rolling direction in
indentation-type roll
0.1
20
RoUer
I
'11(
Could be SpiH
40
10
10
100
Shut Thlcknn1 (mm)
Fig 6. Relative densities with
sheet thickness
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PRICM-5
compressive stress during pressing and the tensile residual stress after exit of pressing in both
surface and center. In case of the large sheet thickness of 60mm in Fig 4b, during roll pressing the
RD stress of the surface is compressive, that of the center is tensile, and at exit of the pressing the
RD residual stresses become reverse; These stress distribution is similar to the alligatoring
condition based on Backofen' s [2] models. It is proved that the sheet thickness must be under 60mm
to hinder in alligatoring.
Fig. 5 shows RD stress distribution along the distance through rolling direction in the
indentation-type roll pressing. In the sheet thickness of 60mm in Fig Sa, overall compressive stress
in surface is observed during pressing but there is high sharp tension peak right before exit of the
pressing. The RD tension residual stress in surface after the exit of the pressing is not reversal stress
state. This stress pattern may not induce alligatoring. As the sheet thickness increase up to 1OOmm as
shown in Fig Sb, the tension peak before the exit of the pressing become low and broad. Therefore,
an assumption can be made that after the exit of the pressing the RD residual stress in surface could
become the reversal stress of the compressive RD stress during roll pressing. This stress state
resembles that of 60mm sheet thickness with flat roller, which may split the compacted sheet. We
expect that the indentation in roll surface hinder in alligatoring phenomenon by making high sharp
tension peak before exit of the pressing. Hence, the indentation could enlarge the critical sheet
thickness by over 60% as illustrate in Fig 6; this is in good accordance with the experimental results.
Conclusion
The experimental result on a critical sheet thickness that leads to the alligatoring is compared with
the analysis of the finite element method based on the yield criterion for powder suggested by Park
et a/. [5] . Numerical analysis shows that the indentation-type roller can offer the critical sheet
thickness 60 percents thicker than the flat roller. The indentation-type roller could offer larger
quantity of the product in the roll pressing process by enlarging the sheet thickness.
Reference
[1] S. W. Choi andY. S. Lee: Metals and Materials Int. Vol8 (2002), p. 25
[2] W.A. Backofen: Deformation Processing, l sr ed. (Addison-Wesley, 1972), p. 151
[3] W. Pietsch : proceedings of lith biennial conference (IBA, 1969), p.145
[4] D.C Drucker and W. Prager: Q. Appl. Math. Vol10(1952), p. 157
[5] S.-J Park, H.N. Han, K.H. Oh and D.N. Lee : Int. J. Mech. Sci. Vol41(1999), p. 121
[6] S.M. Doraivelu, H.L. GeGel, J.S. Gunasekera, J.C. Malas, J.T. Morgan and J.F. Thomas Jr : Int.
J. Mech. Sci., Vol26 (1984), p. 527
[7] H.-J. Chang, H.N. Han, K.-H. Lee, S.-H. Joo, K. H. Oh :proceedings of Euro PM 2003 Vol 3
(EPMA, 2003), p. 91