One of Russula’s bar and section mill customers was having considerable difficulty in rolling UPN 30s without cobbling. Product defects and inconsistent performance were causing significant downtime. Even after readjusting the entire mill passes multiple times, there was still unstable rolling in every UPN 30 campaign. The final product was overfilled, leg length was longer than predicted and frequently out of tolerance.
Time was of the essence. The Russula Rolling Technology Center needed a simulation technology to identify and address design issues that were causing performance and quality issues on two different pass sequences for the same section. Russula reached out to the manufacturer of DEFORM®, Scientific Forming Technologies Corporation (SFTC).
DEFORM® is an engineering software simulator made to analyze complex material processes. It provides a virtual trial run environment that allows production testing on the computer, rather than on the rolling mill itself.
By using DEFORM®, the Russula and SFTC team revealed that the UPN 30 had voids on the 4th, 6th, 7th and 8th forming pass. Overfilling was also occurring on the 6th, 7th and 8th and final pass as well.
The UPN 30 2.5D and 3D simulations helped the team identify the problems and quickly propose workable solutions. The leg length was corrected and the overfill was eliminated. DEFORM® provided a fast, easy model set-up, and was able to capture transient behavior.
Using the DEFORM® software, reduced the amount of time that it would normally take to create a new pass design. The team was able to analyze, simulate and finalize a new design in two weeks. With the optimized pass sequence, the section mill was able to roll UPN 30 cobble-free with no overfill, no defects and within tolerance. It was clear from the start that the collaboration between Russula and SFTC could streamline the operations of many rolling mills in a short timeline.
|PHPSESSID||The PHPSESSID cookie is native to PHP and allows websites to store serialized status data. On the website it is used to establish a user session and to pass status data through a temporary cookie, which is commonly known as a session cookie. These Cookies will only remain on your computer until you close the browser.|
|Google analytics (__utma, __utmb, __utmc, __utmz, _ga)||These cookies are used to collect information about the use of our website by visitors. We use the information to compile reports and to improve the site. Cookies collect information anonymously, which includes the number of visitors to the site, the place of origin of the visitors' site and the pages visited.||More information in Types of cookies used by Google .|
|Youtube(ACTIVITY, APISID, HSID, LOGIN_INFO, PREF, SID, VISITOR_INFO1_LIVE, YSC, demographics, dkv)||YouTube is used to provide useful videos or informational videos. Youtube stores information to be able to generate statistics on the visits of videos embedded in other pages.||More information in Types of cookies used by Google .|
|Google Maps (APISID, HSID, NID, PREF, S, SAPISID, SID, SSID, S_awfe, khcookie)||Show where the offices of our different services are located using Google Maps.||More information in Types of cookies used by Google .|