Este trabalho visa analisar a influência das taxas de resfriamento e temperatura no último passe de laminação a quente de fio máquina de um aço DIN 41Cr4 sobre a microestrutura obtida após a laminação e a sua correlação com aquela resultante do tratamento térmico de esferoidização. Foi avaliado a influência da microestrutura prévia de laminação nos tempos e taxa de resfriamento do tratamento térmico necessários para garantir adequada microestrutura do aço DIN 41Cr4. Foram aplicados conceitos de laminação termomecânica através da variação dos parâmetros: temperatura no último passe de laminação (acabador) e após o último passe de laminação (formador de espiras); velocidade das esteiras do “cooling conveyor” e consequente tempo de permanência das espiras sobre a região de ventiladores e alguns parâmetros no ciclo de tratamento térmico: tempo em patamar e taxa de resfriamento durante a produção de fio máquina redondo de bitolas entre 15,88mm e 16,15mm. A avaliação da resposta às variações impostas ao processo foi realizada através de análises metalográficas de microestrutura no material laminado e no material esferoidizado (grau de esferoidização), descarbonetação e de ensaios de propriedades mecânicas como dureza e tração. A partir dos resultados buscou-se determinar a influência dos parâmetros de laminação na microestrutura do material laminado e a influência desta na resposta ao tratamento térmico de esferoidização. Foram analisadas oito diferentes condições e os resultados mostraram que maiores taxas de resfriamento resultam em microestruturas mais refinadas proporcionando uma simplificação no tratamento térmico, atendendo as propriedades desejáveis no produto final (fio máquina redondo esferoidizado). / This work aims to analyze the influence of the cooling rate, the temperature of the finishing pass and at the coil-forming during hot rolling of DIN 41Cr4 steel wire rod on the microstructure and its influence on plateau times and cooling rate during the spheroidizing heat treatment. For this study thermomechanical rolling concepts were applied through the variation of some hot rolling parameters such as: temperature at the finishing pass and at the coils-former, the cooling conveyor belts velocity and some parameters in the heat treatment cycle: soak temperature and cooling rate during the production of round wire rod with 15,88 mm and 16,15 mm diameter. The evaluation response to changes imposed on the process was evaluated by metallographic analysis of microstructure in hot rolled and spheroidized material (spheroidizing degree), hardness, decarburization and tensile test. Eight rolling conditions and cooling rates were analyzed and results showed that higher cooling rates result in finer microstructures allowing a reduction in heat treatment time to achieve the desirable properties in the final product (spheroidized round wire rod).

In the first part of this thesis, the FE program MSC.Marc is applied for coupled thermomechanical simulations of wire-rod rolling. In order to predict material behaviour of an AISI 302 stainless steel at high strain rates generated during wire-rod rolling, a material model based on dislocation density is applied. Then, the evolution of temperature, strain rate and flow stress is predicted in the first four rolling passes of a wire block. In the second part of the thesis, an alternative approach to simulation of shape rolling is evaluated. The approach is applied in order to save the computational time in cases where many shape-rolling passes are to be simulated. The approach is a combination of the slab method and a 2D FEM with a generalized plane-strain formulation. A number of various isothermal shape-rolling passes are simulated applying the simplified approach. The simulations are carried out using an in-house 2D FE code implemented in Matlab. The results are compared to fully 3D FE analyses. The comparison shows that the simplified approach can predict roll forces and roll torques with a fair accuracy, but the predicted area reductions are a bit underestimated. The reasons for the deviations between the simplified approach and the 3D FEM are discussed. / QC 20101123

<p>In the first part of this thesis, the FE program MSC.Marc is applied for coupled thermomechanical simulations of wire-rod rolling. In order to predict material behaviour of an AISI 302 stainless steel at high strain rates generated during wire-rod rolling, a material model based on dislocation density is applied. Then, the evolution of temperature, strain rate and flow stress is predicted in the first four rolling passes of a wire block.</p><p>In the second part of the thesis, an alternative approach to simulation of shape rolling is evaluated. The approach is applied in order to save the computational time in cases where many shape-rolling passes are to be simulated. The approach is a combination of the slab method and a 2D FEM with a generalized plane-strain formulation. A number of various isothermal shape-rolling passes are simulated applying the simplified approach. The simulations are carried out using an in-house 2D FE code implemented in Matlab. The results are compared to fully 3D FE analyses. The comparison shows that the simplified approach can predict roll forces and roll torques with a fair accuracy, but the predicted area reductions are a bit underestimated. The reasons for the deviations between the simplified approach and the 3D FEM are discussed.</p>

<p>Very often defects are present in rolled products. For wire rods, defects are very deleterious since the wire rods are generally used directly in various applications. For this reason, the market nowadays requires wire rods to be completely defect-free. Any wire with defects must be rejected as scrap which is very costly for the production mill. Thus, it is very important to study the formation and evolution of defects during wire rod rolling in order to better understand and minimize the problem, at the same time improving quality of the wire rods and reducing production costs.</p><p>The present work is focused on the evolution of artificial defects during rolling. Longitudinal surface defects are studied during shape rolling of an AISI M2 high speed steel and a longitudinal central inner defect is studied in an AISI 304L austenitic stainless steel during ultra-high-speed wire rod rolling. Experimental studies are carried out by rolling short rods prepared with arteficial defects. The evolution of the defects is characterised and compared to numerical analyses. The comparison shows that surface defects generally reduce quicker in the experiments than predicted by the simulations whereas a good agreement is generally obtained for the central defect.</p>

Very often defects are present in rolled products. For wire rods, defects are very deleterious since the wire rods are generally used directly in various applications. For this reason, the market nowadays requires wire rods to be completely defect-free. Any wire with defects must be rejected as scrap which is very costly for the production mill. Thus, it is very important to study the formation and evolution of defects during wire rod rolling in order to better understand and minimize the problem, at the same time improving quality of the wire rods and reducing production costs. The present work is focused on the evolution of artificial defects during rolling. Longitudinal surface defects are studied during shape rolling of an AISI M2 high speed steel and a longitudinal central inner defect is studied in an AISI 304L austenitic stainless steel during ultra-high-speed wire rod rolling. Experimental studies are carried out by rolling short rods prepared with arteficial defects. The evolution of the defects is characterised and compared to numerical analyses. The comparison shows that surface defects generally reduce quicker in the experiments than predicted by the simulations whereas a good agreement is generally obtained for the central defect.

Very often defects are present in rolled products. For wire rods, defects are very deleterious since the wire rods are generally used directly in various applications. For this reason, the market nowadays requires wire rods to be completely defect-free. Any wire with defects must be rejected as scrap which is very costly for the production mill. Thus, it is very important to study the formation and evolution of defects during wire rod rolling in order to better understand and minimize the problem, at the same time improving quality of the wire rods and reducing production costs. The present work is focused on the evolution of artificial defects during rolling. Longitudinal surface defects are studied during shape rolling of an AISI M2 high speed steel and a longitudinal central inner defect is studied in an AISI 304L austenitic stainless steel during ultra-high-speed wire rod rolling. Experimental studies are carried out by rolling short rods prepared with arteficial defects. The evolution of the defects is characterised and compared to numerical analyses. The comparison shows that surface defects generally reduce quicker in the experiments than predicted by the simulations whereas a good agreement is generally obtained for the central defect. / QC 20101105

Предметом исследования является производство сортового проката высокого качества. Приведен литературный обзор, включающий в себя некоторые особенности производства сортового проката без дополнительных продольных усилий, описание влияния натяжения и/ил подпора на качество получаемого проката. Выполнена постановка задачи по моделированию прокатки полосы одновременно в трех клетях. Адекватность представленной модели показана путем сравнения результатов моделирования и показаний с действующего стана. Погрешность по формоизменению не превысила 0,4%, по моменту прокатки 11%, что является удовлетворительной сходимостью. На основе разработанной модели спланирован и выполнен расчетный эксперимент по влиянию рассогласования скоростей непрерывной прокатки на технологические параметры процесса. Получены уравнения регрессия описывающие закономерности влияния рассогласования скоростей прокатки на технологические параметры процесса. / The subject of the research is the production of high quality long products. A literature review is presented, which includes some features of the production of bars without additional longitudinal forces, a description of the effect of tension and/or back dam on the quality of the rolled products. The formulation of the problem of modeling rolling bar simultaneously in three stands is completed. The adequacy of the presented model is shown by comparing the simulation results and indications from the rolling mill. The error in the spreading did not exceed 0.4%, at the torque of rolling 11%, which is satisfactory convergence. Based on the developed model, a design experiment was planned and performed on the effect of the mismatch of continuous rolling speeds on the process parameters. The regression equations are obtained that describe the patterns of the influence of mismatch of rolling speeds on the technological parameters of the process.