Automatic measurement and evaluation of flatness of heavy plates for process optimization

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1 ThyssenKrupp Steel Europe Automatic measurement and evaluation of flatness of heavy plates for process optimization Dr. Wolfram Weber, SE R&D Dr. Hans-Jürgen Kaiser, Olaf Ehrich, SE HP Michael Krauhausen, nokra ThyssenKrupp Steel Europe

2 Outline Properties and application of heavy steel plates Process steps during rolling, quenching, and tempering of heavy plates Application of flatness measurement for quality assurance Automatic classification of flatness defects for leveler setup Achieved process improvements Conclusion

3 Properties and application of heavy steel plates Heavy plate unit (SE-HP) Plate dimensions: length: width: thickness: Applications : 6 25 m mm mm Production facilities : AR, TM, Q, QT highly stressed structures in mobile cranes, construction equipment, trucks, mining structures, vehicle and building protection

4 Process steps during rolling, quenching, and tempering roll stand (four-high reversing mill) rolling force: 8500to max. plate weight: 14to hot leveler process steps: reheating of slabs rolling hot leveling cooling and stacking

5 Process steps of heat treatment of heavy plates heat treatment = quenching (1) and tempering (2) objective: setting the relation of hardness and ductility of the plates (1) quenching to induce martensite formation continuous conveyer furnace water quenching unit process step: reheating of plates rapid cooling

6 Process steps of heat treatment of heavy plates (2) tempering (adjustment of ductility): depending on the temperature, residual stress within the plate is reduced, martensite will be partly transformed 80 m annealing furnace hot / cold leveler process steps: reheating of the plates hot or cold leveling

7 Plant layout and locations of the flatness gauges hot leveler cold leveler flatness gauge hot and cold leveler flatness gauge flow of information Objectives of the flatness gauges total quality control according to DIN EN fast feedback for individual setup of the leveler (second pass)

8 Interaction of levelers and automated flatness gauges principle of leveling Zone 1 distension Zone 2 removal of material stresses tensile stress +σ plastic deformation direction of transportation plate thickness -σ compressive stress bending radius elastic zone plastic deformation requirements for data processing of the flatness gauges automatic feedback to the leveler: automatic feedback to the production process: provision of basic information about plate topography, which can be used by the leveling model automatic identification and classification of flatness defects (position and characteristics) analysis of the characteristics for optimized set up of the next leveling pass verification of compliance to customer requirements, e.g. DIN EN automatic initiation of an additional leveling pass or heat treatment

9 Measurement of flatness for quality control and process feedback measurement principle: laser triangulation using optical distance measurements to capture the plate topography during transport of the plate along the conveyor benefits of laser measurement: low disturbances by ambient light due to high light intensity high dynamics for measurement on varying surface properties low cost of operation and maintenance due to high lifespan of laser diodes

10 Example of flatness measurement 3D view of the topography Verification of the customer requirements according DIN EN 10029

11 Typical defects for classification Defect Edge wave Description Wavelength between 150mm and 2000mm. Two tracks (100mm from the edges) are examined. Presentation Buckle Symmetric curvature in both directions. Field of examination e.g. 500mm x 500mm Bathtub / Turtle Identically oriented curvature over a certain length (Usual value = half of plate length) Ski Same orientation of longitudinal cuts with a length of 3m at plate ends

12 Classification of flatness defects max. amplitude frequencies plate width [m] I-Unit, variations of fiber length dimension and position of defects plate length [m]

13 Determination of threshold values through process analysis characteristic value: edge wave (histogram) edge wave (amplitude) first threshold second threshold frequency amplitude [mm]

14 Representation of plate classification Defined thresholds bath tub < 13 > 13 class height/ amplitude in mm edge wave 1 0,6 edge wave 2 0,5 edge wave < 0,4 > 0,4 buckle < 9 > 9 I-unit < 0,1 > 0,1 buckle ( 1/2 plate width ) buckle ( 1/4 plate width ) 9,5 3,8 bath tub 0 turtle 0 ski at the back 0 I-unit lengthwise 0,6 I-unit lateral 0,2

15 Closed loop of leveling and flatness measurement leveler plate flatness after rolling and tempering final plate flatness classification result class edge wave 1 edge wave 2 buckle (1/2 width) buckle (1/4 width) bath tub turtle ski at back I-Unit lengthwise I-Unit lateral value 0,3 0,4 5,9 2,7 0 9,5 0 0,06 0,09 flatness gauge plate flatness ThyssenKrupp Steel Europe

16 Achieved process improvement High-strength tempered heavy plates with thickness 12 to 40 mm plates with flatness defects outside custumer requirements after first leveling pass produced plates: Platen quench device Roller quencher /08 08/09 09/10 Flatness gauges lead to an overall improvement of production processes ThyssenKrupp Steel Europe

17 Conclusion Substantial investments were made to improve the production processes (furnaces, quench line, leveler, flatness gauge) Total documentation of plate flatness through automatic flatness measurement at the end of the production steps Development and implementation of a closed loop process for leveling comprising leveler and flatness gauge Flatness measurement supports the improvements of the production process ThyssenKrupp Steel Europe

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