Phase diagrams CCT and CCCT; Transformation kinetics. Flow curves with realistic deformation conditions. (temperature, strain rate and strain)

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1 Prace IMZ 1 Dodatek (2012) Semi-industrial scale simulation of processes... 47

2 48 Rudolf Kawalla, Gerd Goldhahn, Grzegorz Korpala Prace IMZ 1 Dodatek (2012) Test and Pilot Facilities Order administration and processing Development of facilities Basics of Metal Forming Material constants Flow curves Basic data Structure of the Institute Prof. Dr.-Ing. R. Kawalla Prof. Dr.-Ing. habil G. Lehmann Characteristic Material Parameters Development of Materials and Technology of Flat Products Development of Materials and Technology of Long and Massive Products Numerical Simulation Characteristic data of materials and technology in metal forming processes Physical properties Models for description of metal forming behaviour Models for microstructure evolution and forming processes Models for mechanical properties New materials and technologies Methods and models for calibration Rod, bar, sheet metal forming and drawing Forging technology Powder metallurgy FEM / FD Network System development 2 Focus of Research Modelling Materials Technology New Materials Material Flow Microstructure evolution Mechanical properties Material behaviour at production, further processing and of the final product Numeric simulation systems Rolling Forging Drawing Sheet metal forming Further treatment High strength steels Cladded materials Compound materials Light alloys Magnesium Aluminium FeSi Steels Special materials 3 Material Data for Modelling (Macroscopic Phenomenological Models) Phase diagrams CCT and CCCT; Transformation kinetics Flow curves with realistic deformation conditions (temperature, strain rate and strain) Dynamic and static recovery and recrystallisation kinetics; effects of alloying elements on these characteristics 4 Main Activities Experimental and Theoretical Work on - Material Flow - Evolution of Microstructure 5

3 Prace IMZ 1 Dodatek (2012) Semi-industrial scale simulation of processes Material Science: Development of Materials - Complexity Technique Technology Microstructure/Texture Properties 6 Material Science: Development of Materials - Complexity Topic: Technique Technology Metal Forming 7 Material Science: Development of Materials - Complexity Topic: Technology - Microstructure Grain Structure, Texture, Precipitation 8 Material Science: Development of Materials-Complexity Topic: Technology - Properties Mechanical Properties 9

50 Rudolf Kawalla, Gerd Goldhahn, Grzegorz

Methods of the Institute for Metal Forming: Flow

Behaviour Rolling Mills Torsion Plastometers

Stand Continuous Speed Rolling Mill with

Reversing Stand Mill (Duo/Quarto) Duo Cold

.. 1200 C Plastometer II max 30 s -1 max 700.

Dynamic Material Testing up to 1200 C 40 s -1 F =

HDS-V40 Metallographic Lab Dynamic Systems

Gleeble 12 Flat upsetting test with steel in 3

4 50 Rudolf Kawalla, Gerd Goldhahn, Grzegorz Korpala Prace IMZ 1 Dodatek (2012) Experimental Methods of the Institute for Metal Forming: Flow Curve Characteristic and Recristallization Behaviour Rolling Mills Torsion Plastometers Servohydraulic Testing Systems Four/Five High Stand Continuous Speed Rolling Mill with different cooling lines Open Three Stand Mill Reversing Stand Mill (Duo/Quarto) Duo Cold Rolling Mill Plastometer I max 15 s -1 RT C Plastometer II max 30 s -1 max C Tension, Upsetting, Bending Test Dynamic Material Testing up to 1200 C 40 s -1 F = 40 kn Duo / Quarto Cold Rolling Mill Gleeble HDS-V40 Metallographic Lab Dynamic Systems Universal hot and cold rolling simulator 10 Gleeble 12 Flat upsetting test with steel in 3 passes at 1000 C (phi=0.3)(phip=0.5; 5.0; /s) Gleeble: Multi Step Upsetting Test; Modelling a Continuous Hot Rolling 13

Prace IMZ 1 Dodatek (2012) Semi-industrial scale simulation of

3 Alloy Experimental Procedure: Compression Test Austenitize 1

in Air (~ 1K/s) First Pass U 800-850-900 C 1 = 0,51 = 1, 10, 25 s

Melting Tension Test MaxStrain-Test Planar Compression Uniaxial

Daten Plastometer 400 (statisch) Prükraft [kn] 320 (dynamisch)

480 Hub [mm] ±50 Lift [mm] ± 50 Antriebsleistung [kw] 75 Power

Deformation oder Umformgrad Degree Load Statically, Fluctuating,

Deformation Belastung Temperature [ C] oder schwingend 20 1200

Delay Time [s] 0 15 Umformgeschwindigkeit Test Methods [1/s]

5 Prace IMZ 1 Dodatek (2012) Semi-industrial scale simulation of processes Static Softening of FeSi1.3 Alloy Experimental Procedure: Compression Test Austenitize 1 min at 1150 C Time between the Passes: t p = 0, s Cooling in Air (~ 1K/s) First Pass U C 1 = 0,51 = 1, 10, 25 s -1 Second Pass 2 = 0,07 Cooling in Air Time 14 Gleeble HDS-V40 Melting Tension Test MaxStrain-Test Planar Compression Uniaxial Compression 15 Servohydraulic System (Plastometer) Technische Daten Plastometer 400 (statisch) Prükraft [kn] 320 (dynamisch) Technical Parameters Plastometer Prüfgeschwindigkeit Test Load [kn] [mm/s] (statically) 320 (dynamically Testing Speed [mm/s] Hub [mm] ±50 Lift [mm] ± 50 Antriebsleistung [kw] 75 Power [kw] 75 Control Mode Force, Stroke, Steuerung Kraft, Weg, Deformation oder Umformgrad Degree Load Statically, Fluctuating, Oscillating Deformation Rate [1/s] ruhend, schwellend max 40 Deformation Belastung Temperature [ C] oder schwingend Possible. Delay Time [s] 0 15 Umformgeschwindigkeit Test Methods [1/s] Cylinder-, max. Hollow 40 Cylinder, Cone-, Flat Compression Test Prüftemperatur [ C] Max. Pausenzeit [s] 0 15 Versuchsmethoden Zylinder-, Kegel-, Hohlzylinder- Flachstauchversuch 16 Servohydraulic System (Plastometer) 17 Temperature

52 Rudolf Kawalla, Gerd Goldhahn, Grzegorz Korpala Prace IMZ 1 Dodatek (2012)

..15 Power [kw] 2 Nominal Torque [Nm] 23.

Off-Time [s] 0.15 Temperature [ C] 0...1200 Deform. Rate [1/s] max.

0,8 0,64 0,48 0,32 0,16 Torsion Plastometer 18 softening c max.

DRX 0 0,16 0,32 0,48 0,64 0,8 0,96 1,12 Strain 19 0 X Xdyn Flow stress Use of

Treatment Continuous Pilot Mill (Flat) Continuous Hot Strip Pilot Mill (4

interstand cooling, finish cooling line, coiler and holding furnace (both for

distances between 1,5m and 7,5m, finish rolling speed: 10 (20 m/s) finish strip

6 52 Rudolf Kawalla, Gerd Goldhahn, Grzegorz Korpala Prace IMZ 1 Dodatek (2012) Technical Parameters Specimen Dimension [mm] Plastometer 6 x Power [kw] 2 Nominal Torque [Nm] 23.5 Overload Capacitity 5 Speed Range [1/min] Min. Angle of Torque [ ] Min. Off-Time [s] 0.15 Temperature [ C] Deform. Rate [1/s] max Hardening and Softening: 144,89 124,89 104,89 84,89 64,89 44,89 24,89 0,96 0,8 0,64 0,48 0,32 0,16 Torsion Plastometer 18 softening c max. ss 0 0,16 0,32 0,48 0,64 0,8 0,96 1,12 Strain Steady state 0,5 Beginn Start of DRX 0 0,16 0,32 0,48 0,64 0,8 0,96 1,12 Strain 19 0 X Xdyn Flow stress Use of Plastometer to determine the material behaviour Hot Rolling Cold Rolling Heat Treatment Continuous Pilot Mill (Flat) Continuous Hot Strip Pilot Mill (4 Stands) Inductive heating (1350 C), descaler (450 bar), roll gap lubrication, interstand cooling, finish cooling line, coiler and holding furnace (both for controlled strip cooling), single drives and movable stands with variable stand distances between 1,5m and 7,5m, finish rolling speed: 10 (20 m/s) finish strip thickness: 5-1 mm Reversing mills (Two-High, Four-High) finish rolling speed: max (2 m/s) finish strip thickness: 3-0,1 mm Inert gas furnace, reheating and heat treatment furnaces 21

7 Prace IMZ 1 Dodatek (2012) Semi-industrial scale simulation of processes Continuous Pilot Mill (Flat) Inductor, Rolling Side Inductor, Drive Side Reversing Roughing Mill 23 Coiler (open) Continuous Pilot Mill (Flat) Coil Boxes for controlled Cooling Continuous Pilot Mill (Flat) Continuous Finishing Line

54 Rudolf Kawalla, Gerd Goldhahn, Grzegorz Korpala Prace IMZ 1 Dodatek (2012) Continuous Pilot Mill (Bar and Rod) Cooling

Stelmor Band Lead Bath Thermo Pot Descaler Water Pressure P max = max 450 bar Raw Material H : : 10 10 - - 45 45 mm W : :

2500 mm 5500 mm Roughing Mill D = 295 - - 340 mm F max max = 1600 kn M max = max 30 30 kn m v max max = 6 m/s Driver

Mill (Bar and Rod) Hot Rolling Continuous Rod and Bar Pilot Mill (5 Stands) Inductive heating (1350 C), descaler (450 bar),

cooling, patenting etc., single drives and movable stands with variable stand distances between 1,5m and 7,5m.

8 54 Rudolf Kawalla, Gerd Goldhahn, Grzegorz Korpala Prace IMZ 1 Dodatek (2012) Continuous Pilot Mill (Bar and Rod) Cooling Line 4 Finish Mills H V H V D = 200 mm F max max = 200 kn M max max = kn m v 4max = 4max m/s Laying Head with Stelmor Band Lead Bath Thermo Pot Descaler Water Pressure P max = max 450 bar Raw Material H : : mm W : : mm L : : max mm 5500 mm Roughing Mill D = mm F max max = 1600 kn M max = max kn m v max max = 6 m/s Driver Inductive/Conductive Heating T max max = 1350 C C Pilot Mill, Configuration for Rod and Bar Rolling 26 Continuous Pilot Mill (Bar and Rod) Hot Rolling Continuous Rod and Bar Pilot Mill (5 Stands) Inductive heating (1350 C), descaler (450 bar), roll gap lubrication, interstand cooling, finish cooling line, laying head, Stelmor band, thermo pot for quenching, slow cooling, patenting etc., single drives and movable stands with variable stand distances between 1,5m and 7,5m. finish rolling speed: 75 m/s, 5mm Reversing Mill (Sheets, Bars, Rods, Rails) Open Three Stand Three-High Mill (Termomechan. Rolling) Cold Deform. Bar and Tube Drawing Machine, Bull-Block Machine Heat Treatment Inert Gas Furnace, Reheating and Heat Treatment Furnaces 27 Continuous Pilot Mill (Bar and Rod) Continuous Pilot Mill (Long Products) initial material C45-45x45 square hot rolling (revers) in 10 steps to Ø 12mm hot rolling (continuous) in 4 steps to Ø 8,5mm cooling continuous TMT 28 29

Prace IMZ 1 Dodatek (2012) Semi-industrial scale simulation of processes.

Open Three Stand Mill Duo/Quarto-Cold Rolling Mill Duo-Cold Rolling Mill 31

bonding) configuration 2- high / 4 high investigation of the evolution of

2000kN P max = 100kW h 0 = 7mm / 1mm (2-high/4high) h 1 = 0.5mm / 0.

strip width: 140mm diameter of work roll: 65 / 85 / 260 mm max.

9 Prace IMZ 1 Dodatek (2012) Semi-industrial scale simulation of processes Hot Rolling Mills Reversing Mill (Two-high / Four-high, Universal Mill) Open Three Stand Mill Duo/Quarto-Cold Rolling Mill Duo-Cold Rolling Mill 31 Duo-/ Quarto Cold Rolling Mill process simulation (cold rolling, cold roll bonding) configuration 2- high / 4 high investigation of the evolution of texture under real process conditions F study of tribological aspects max = 2000kN P max = 100kW h 0 = 7mm / 1mm (2-high/4high) h 1 = 0.5mm / 0.1mm (2-h / 4-h) max. strip width: 140mm diameter of work roll: 65 / 85 / 260 mm max. rolling speed: 2m/s 32 Massive Working Free Forging Die Forging Die Pressing Cast Forging Thixoforming Extrusion Powder Forging Sheet Deformation Deep Drawing Press Hardening 10MN Forging Press 33

10 56 Rudolf Kawalla, Gerd Goldhahn, Grzegorz Korpala Prace IMZ 1 Dodatek (2012) Annealing Furnace (Simulation of Continous Annealing Lines) 35 Technical Data Radiation Furnace Maximum Temperature [ C] 1100 Heating Rate [K/s] up to 80) Cooling Rate [K/s] up to 60) Sample Dimensions [mm] 140 x 80 x 0,3-2 (Standard) 230 x 90 x 0,3-2 (Maximum) Gas Atmosphere Anneling Nitrogen;Cooling in H2 or forming gas, 36 Box Annealing maximale Temp C T = 2 K Volume: 120 mm x h = 250 mm Vacuum: 10-5 mbar Atmosphere: Inert Gas, Hydrogen, Vacuum 37

11 Prace IMZ 1 Dodatek (2012) Semi-industrial scale simulation of processes Testing Machines Universal Testing Machine AG 100 Sheet Testing Machine BUP 600 Technical Parameters of Universal Testing Machine AG 100 Technical Data AG100 Force [kn] 100 Cross Beam Stroke [mm] Cross Beam Rate [mm/min] , Rigidity [kn] 300 Number of Rotations [1/min] Extern Meassuring Systems Contactless System ME46 Video-Extensiometer for Longitudinal and Transversal Extension at RT Contact System Maytec for Longitudinal Extension at Hot Tensile Tests Clamping Tools Temperature Control Shouldered and Threaded Specimens Infrared Radiation Furnace C Universal Testing Maschine AG Erichsen Test 41

12 58 Rudolf Kawalla, Gerd Goldhahn, Grzegorz Korpala Prace IMZ 1 Dodatek (2012) Measurement Technique for Soft Magnetic Materials MPG 100 Brockhaus Measuring Technique DC, AC bis 10 khz; Single Strips, Rings Erichsen Test 42

MANUFACTURING PROCESSES

1 MANUFACTURING PROCESSES - AMEM 201 Lecture 8: Forming Processes (Rolling, Extrusion, Forging, Drawing) DR. SOTIRIS L. OMIROU Forming Processes - Definition & Types - Forming processes are those in which