Method of emulsion concentration optimization for cold continuous rolling mill set

Disclosed is a method of emulsion concentration optimization for a cold continuous rolling mill set for achieving vibration suppression, the method comprising: defining the process parameters involved in the process of emulsion concentration optimization; setting an initial set value of an emulsion concentration comprehensive optimization target function for a cold continuous rolling mill set for achieving vibration suppression; calculating a bite angle of each stand; calculating a vibration determination index reference value of each stand; setting the emulsion concentration of each stand; calculating the outlet temperature of a strip steel of each stand; calculating the dynamic viscosity of an emulsion in a roll gap of each stand; calculating the oil film thickness in the roll gap of each stand; calculating the emulsion concentration comprehensive optimization target function; determining whether the inequation F(X)<F0 is established; determining whether the concentration of the emulsion exceeds a feasible region range, and outputting the optimal emulsion concentration set value.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a 371 U.S. National Phase of PCT International Application No. PCT/CN2019/101118 filed on Aug. 16, 2019, which claims benefit and priority to Chinese patent application no. 201811144978.X filed on Sep. 29, 2018, contents of both are incorporated by reference herein in their entireties.

TECHNICAL FIELD

The present invention belongs to the field of cold continuous rolling, and in particular relates to a method of emulsion concentration optimization for a cold continuous rolling mill set for achieving vibration suppression.

BACKGROUND

As an important process parameter in the process lubrication system, emulsion concentration plays a vital role in the lubrication status of the roll gap of each stand of the cold continuous rolling mill set.

At the same time, the lubrication status of the roll gap directly affects the occurrence of vibration defects of the rolling mill.

If the roll gap is in an over-lubricated status, the friction coefficient is too small, which is likely to cause slip in the rolling process and leads to self-excited vibration of the rolling mill. If the roll gap is in an under-lubricated status, the average oil film thickness in the roll gap is less than the required minimum value, which is likely to cause the oil film in the roll gap to crack during the rolling process and leads to the sharp increase of the friction coefficient, thus changing the rolling pressure, causing the periodic fluctuation of the system stiffness and causing the self-excited vibration of the rolling mill as well.

In the past, the site generally relies on the speed of the rolling mill to suppress the occurrence of vibration defects, but this operation restricts the improvement of the production efficiency of the cold continuous rolling mill set and seriously affects the economic benefits of the enterprise.

The Chinese invention patent with the authorized announcement number of CN 103544340 B and the authorized announcement date of Mar. 2, 2016 discloses a “Method for Setting Emulsion Concentration in Extremely Thin Strip Rolling of Five-stand Cold Continuous Rolling Mill Set”. The method for setting emulsion concentration includes the following steps executed by a computer: 1) acquiring the main equipment of the mill set, the characteristics of the strip to be rolled, the main rolling process and the process lubrication system parameters; 2) defining relevant process parameters; 3) calculating the roll bending force and roll shifting amount; 4) assigning values to relevant search process parameters; 5) calculating concentration process parameters; 6) calculating the search process speed of the maximum rolling speed; 7) calculating the friction coefficient of each stand under the current conditions; 8) calculating the rolling force, rolling power, slip factor, thermal slip injury index and vibration coefficient of each stand under the current conditions; 9) calculating the thermal crown of the work roll of each stand; 10) calculating the outlet plate shape and the forced-contact width; and 11) obtaining and outputting the optimum proportion concentration. It can be seen that the patent aims at improving the rolling speed, ensuring the rolling efficiency, and avoiding slipping, thermal slip injury and vibration, so as to ensure the outlet plate shape of the final stand and the minimum forced-contact width at the work roll end.

Through research, it is found that under the premise of determining the process parameters such as rolling schedule, roll process, emulsion flow rate and initial temperature, the setting of emulsion concentration directly determines the lubrication status of the roll gap of each stand of the cold continuous rolling mill set, and can be used as the main process control means to suppress the vibration of the rolling mill.

However, at present, there has not been a report providing the technical solution of suppressing the vibration of the rolling mill by changing the previous mode of constant concentration control of an emulsion in each stand and taking the concentration of the emulsion in each stand as a variable to be optimized.

SUMMARY

The technical problem to be solved by the invention is to provide a method of emulsion concentration optimization for a cold continuous rolling mill set for achieving vibration suppression. The method changes the previous mode of constant concentration control of the emulsion in each stand, takes the concentration of the emulsion in each stand as a variable to be optimized, and carries out comprehensive optimization control on emulsion concentration. The lubrication status of roll gaps in each stand is optimized through the reasonable proportion of emulsion concentration in each stand, thus achieving the purposes of suppressing vibration of the rolling mill, improving product quality and production efficiency, and bringing economic benefits to enterprises.

The technical solution of the invention is to provide a method of emulsion concentration optimization for a cold continuous rolling mill set for achieving vibration suppression, wherein the method includes the following steps:

(a) acquiring apparatus characteristic parameters of a cold continuous rolling mill set;

(b) acquiring critical rolling process parameters of a strip material;

(c) acquiring process parameters involved in the process of emulsion concentration optimization;

(d) setting an initial set value F0=1.0×1010of an emulsion concentration comprehensive optimization target function for a cold continuous rolling mill set for achieving vibration suppression;

the executing order of steps (a) to (d) is not limited;

(e) calculating a bite angle αiof each stand;

(f) calculating a vibration determination index reference value ξ0iof each stand;

(g) setting an emulsion concentration Ciof each stand;

(h) calculating the outlet temperature Tiof a strip steel of each stand;

(i) calculating the dynamic viscosity η0iof an emulsion in a roll gap of each stand;

(j) calculating an oil film thickness ξiin the roll gap of each stand;

(k) calculating the emulsion concentration comprehensive optimization target function F(X);

(l) determining whether the inequation F(X)<F0, is established, if yes, then setting Ciy=Ci, F0=F(X) and turning to step (m); if no, directly turning to step (m);

(m) determining whether the emulsion concentration Ciexceeds the range of a feasible region, if yes, turning to step (n); if no, turning to the step (g); wherein the feasible region refers to a region from 0 to the maximum emulsion concentration allowed by an apparatus, and wherein the allowed emulsion concentration of the apparatus is usually within 10%, and 0˜10% can be set as the feasible range;

(n) outputting the optimal emulsion concentration set value Ciy, wherein Ciyis the value of Ciwhen the calculated value of F(X) is minimum in the feasible region; and

(o) adjusting and controlling the emulsion concentration of each stand according to the optimal emulsion concentration set value Ciyin the step (n) by a control system of the cold continuous rolling mill set.

wherein calculating the vibration determination index reference value ξ0iof each stand in the step (f) comprising the following steps:

(f1) calculating an over-lubricated oil film thickness critical value ξi+of each stand as follows:

it is assumed that when

γiαi=A+,
the roll gap is just in an over-lubricated status, wherein γiis a neutral angle of each stand, and A+is an over-lubricated determining coefficient;

calculating to obtain

ui+=12⁢(2⁢A+-1)⁢(Δ⁢hiRi′+Ti⁢0-Ti⁢1Pi)
according to

αi=Δ⁢hiRi′,
wherein Δhiis the rolling reduction, Δhi=h0i−h1i, h0iis the inlet thickness of each stand, h1iis the outlet thickness of each stand, and Ri′ is the flattening radius of a work roll of the ithstand,

wherein T0iis the back tension of each stand, T1iis the front tension of each stand, and Piis the rolling pressure of each stand,

according to the relationship between the friction coefficient and the oil film thickness: ui=ai+bi·eHi·ξi, wherein aiis the liquid friction influence coefficient, biis the dry friction influence coefficient, and Biis the friction coefficient attenuation index, the over-lubricated oil film thickness critical value ξi+of each stand is calculated by:

(f2) calculating an under-lubricated oil film thickness critical value ξi−of each stand as follows:

it is assumed that when

γiαi=A-,
the roll gap is just in an under-lubricated status, wherein A−is the under-lubricated determining coefficient, the following equation can be obtained:

and the under-lubricated oil film thickness critical value ξi−of each stand is calculated by:

ξi-=1Bi⁢ln⁢ui--aibi;
and

(f3) calculating the vibration determination index reference value ξ0iof each stand as follows:

wherein calculating the outlet temperature Tiof the strip steel of each stand in the step (h) comprising the following steps:

(h1) calculating the outlet temperature T1of the first stand:

wherein T1Inletis the inlet temperature of each stand,

εi=Δ⁢hih0⁢i,
Δhi=h0i−h1i, h0iis the inlet thickness of each stand, h1iis the outlet thickness of each stand, ρ is the density of strip steel, S is the specific heat capacity of strip steel, J is the mechanical equivalent of heat, and Kiis the resistance to deformation of the strip steel of each stand;

(h2) setting i to 1;

(h3) setting the temperature of the first section of strip steel behind the outlet of the ithstand to Ti, 1, i.e., Ti, 1=Ti;

(h4) setting j to 2;

(h5) the relationship between the temperature of the jthsection and the temperature of the j−1thsection satisfies the following equation:

wherein k0is the influence coefficient of nozzle shape and spraying angle, 0.8<k=0<1.2, w is the flow rate of the emulsion, l is the distance between stands, and the distance l between stands is equally divided into m sections, the temperature in the section is represented by Ti, j, v1iis the outlet speed of each stand, h1iis the outlet thickness of each stand, ρ is the density of the strip steel, S is the specific heat capacity of the strip steel, Tiis the outlet temperature of each stand, and Tcis the temperature of the emulsion;

(h6) determining whether the inequation j<m is established, if yes, then setting j=j+1 and turning to the step (h5); if no, turning to step (h7);

(h7) obtaining the temperature Ti,mof the mthsection via iterative calculation;

(h8) calculating the inlet temperature Ti+1Inletof the i+1thstand:
Ti+1Inlet=Ti,m;

(h9) calculating the outlet temperature Ti+1of the i+1′ stand;

(h10) determining whether the inequation i<n is established, if yes, setting i=i+1 and turning to the step (h3); if no, turning to step (h11); and

(h11) obtaining the outlet temperature Tiof each stand.

Specifically, apparatus characteristic parameters of the cold continuous rolling mill set at least include:

the radius Riof a work roll of each stand; the surface linear speed vriof a roll of each stand; the original roughness Rair0of a work roll of each stand; the roughness attenuation coefficient BL, of a work roll; the distance l between stands; and rolling kilometers Liof a work roll of each stand after roll change; wherein i=1, 2, . . . , n; i represents the ordinal number of the stand of the cold continuous rolling mill set, and n is the total number of the stands.

Specifically, the critical rolling process parameters of the strip material at least include:

the inlet thickness h0iof each stand; the outlet thickness h1iof each stand; the width B of the strip steel; the inlet speed v0iof each stand; the outlet speed v1iof each stand; the inlet temperature T1Inlet; the resistance to deformation Kiof the strip steel of each stand; the rolling pressure Piof each stand; the back tension T0iof each stand; the front tension T11of each stand; the concentration influence coefficient kcof the emulsion; the viscosity compression coefficient θ of a lubricant; the density ρ of the strip steel; the specific heat capacity S of the strip steel; the flow rate w of the emulsion; the temperature Tcof the emulsion; and the mechanical equivalent of heat J.

Specifically, the process parameters involved in the process of emulsion concentration optimization at least include: the over-lubricated oil film thickness critical value ξi+and the corresponding friction coefficient ui+of each stand; the under-lubricated oil film thickness critical value ξi−and the corresponding friction coefficient ui−of each stand; the vibration determination index reference value ξ0i; the rolling reduction Δhi=h0i−h1i; the rolling reduction ratio

εi=Δ⁢hih0⁢i;
the inlet temperature TiInletof each stand; and the outlet temperature Tiof each stand; the distance l between stands, which is equally divided into m sections, the temperature in the section represented by Ti, j, wherein 1≤j≤m and TiInlet=Ti−1,m; the over-lubricated determining coefficient A+; and the under-lubricated determining coefficient A−.

Further, the calculation formula for calculating the bite angle αiof each stand is as follows:

αi=Δ⁢hiRi′
wherein Ri′ is the flattening radius of the work roll of the ithstand, and is a process value in rolling pressure calculation.

Further, the calculation formula for calculating the dynamic viscosity η0iof the emulsion in the roll gap of each stand is as follows:
η0i=b·exp(−a·Ti)

wherein a and b are dynamic viscosity parameters of the lubricant under atmospheric pressure.

Further, the calculation formula for calculating the oil film thickness ξiin the roll gap of each stand is as follows:

wherein h0iis the inlet thickness of each stand, h1iis the outlet thickness of each stand, kcis the emulsion concentration influence coefficient, θ is the viscosity compression coefficient of the lubricant, Kiis the resistance to deformation of the strip steel of each stand, η0iis the dynamic viscosity of the emulsion in the roll gap of each stand, v0iis the inlet speed of each stand, vriis the surface linear speed of a roll of each stand, T0iis the back tension of each stand, B is the width of the strip steel, krgrepresents the coefficient of the strength of the surface longitudinal roughness of the work roll and the strip steel to entrain the lubricant, the value of which is from 0.09 to 0.15, Krsrepresents the impression rate, i.e., the ratio of transmitting surface roughness of the work roll to the strip steel, the value of which is from 0.2 to 0.6, Rair0is the original roughness of a work roll of each stand, BLis the roughness attenuation coefficient of the work roll, and Liis the rolling kilometers of a work roll of each stand after roll change.

Further, the emulsion concentration comprehensive optimization target function is calculated according to the following formula:

wherein x={Ci} is an optimized variable, and λ is a distribution coefficient.

In the disclosure, as long as the execution of the next step is not conditional on the result of the previous step, it is not necessary to proceed according to the above order, unless the execution of the next step depends on the previous step.

Compared with the prior art, the invention has the following advantages:

1. The lubricated status of roll gaps in each stand is optimized through reasonable proportion of the emulsion concentration of each stand, thus achieving the purposes of suppressing vibration of the rolling mill, and improving product quality and production efficiency.

2. As a result of a large number of field tests and theoretical research, based on the apparatus characteristics and rolling process features of the cold continuous rolling mill set, a method of emulsion concentration optimization for a cold continuous rolling mill set for achieving vibration suppression is put forward. The method realizes the optimal ratio of emulsion concentration for each stand of the cold continuous rolling mill set, achieves suppressing vibration of the rolling mill and improving product quality and production efficiency, and brings great economic benefits to enterprises.

DETAILED DESCRIPTION

The invention will be further described below in conjunction with the accompany drawings and embodiments.

In order to further explain the application process of the related technologies mentioned in the invention, a1730cold continuous rolling mill set of a cold rolling plant is taken as an example. The application process of the method of emulsion concentration optimization for a cold continuous rolling mill set for achieving vibration suppression is described in detail.

At first, according to the various steps shown inFIG.1, the relevant parameters are determined in turn. Then the parameters are substituted into corresponding formulas for calculation, and the desired optimal emulsion concentration set value Ciyis determined or obtained. Finally, the emulsion concentration of each stand is controlled according to the determined optimal emulsion concentration set value, and the comprehensive optimization control is carried out to achieve suppressing the vibration of the rolling mill.

Specifically, in the step (a), the acquired apparatus characteristic parameters of a cold continuous rolling mill set mainly include:

the radius of a work roll of each stand: Ri={210, 212, 230, 230, 228} mm;

the surface linear speed of a roll of each stand: vri={180, 320, 500, 800, 1150} m/min;

the original roughness of a work roll of each stand: Rair0={1.0, 1.0, 0.8, 0.8, 1.0} um;

the roughness attenuation coefficient of the work roll: BL=0.01;

the distance between stands: l=2700 mm; and

the rolling kilometers of a work roll of each stand after roll change: Li={100, 110, 230, 180, 90} km; wherein i=1, 2, . . . , n; i represents the ordinal number of the stand of the cold continuous rolling mill set; and n=5, which is the total number of the stands, the same below;

subsequently, in the step (b), the acquired critical rolling process parameters of the strip material mainly include:

the width of the strip steel: B=966 mm;

the resistance to deformation of the strip steel of each stand:

the concentration influence coefficient of the emulsion: kc=0.9;

the viscosity compression coefficient of the lubricant: θ=0.034;

the density of the strip steel: ρ=7800 kg/m3;

the specific heat capacity of the strip steel: S=0.47 kJ/(kg·° C.);

the flow rate of the emulsion: w=900 m/min;

the temperature of the emulsion: Tc=58° C.;

the mechanical equivalent of heat: J=1; and

the flattening radius of the work roll of the it stand: Ri′={278.2, 279.7, 300.5, 301.6, 295.4};

subsequently, in the step (c), the acquired process parameters involved in the process of emulsion concentration optimization mainly include: the over-lubricated oil film thickness critical value ξi+and the corresponding friction coefficient ui+of each stand; the under-lubricated oil film thickness critical value ξi−and the corresponding friction coefficient ui−of each stand; the vibration determination index reference value ξ0i, the rolling reduction: Δhi=h0i−h1i={0.86, 0.51, 0.2, 0.15, 0.1}; the rolling reduction ratio:

εi=Δ⁢hih0⁢i={0.4⁢3,0.4⁢5,0.3⁢2,0.3⁢5,0.3⁢6};
the inlet temperature TiInleteach stand; and the outlet temperature Tiof each stand; the distance l between stands is 2700 mm, which is equally divided into m=30 sections, the temperature in the section is represented by Ti, j(wherein 1≤j≤m), and TiInlet=Ti−1,m; the over-lubricated determining coefficient A+; and the under-lubricated determining coefficient A−.

subsequently, in the step (d), an initial set value F0=1.0×1010of an emulsion concentration comprehensive optimization target function for a cold continuous rolling mill set for achieving vibration suppression is set;

subsequently, in the step (e), the bite angle αiof each stand is calculated according to the rolling theory using the calculation formula:

subsequently, in the step (f), the vibration determination index reference value ξ0iof each stand is calculated according to the sub-steps shown in theFIG.2:

(f1) calculating the over-lubricated oil film thickness critical value ξi+of each stand:

it is assumed that when

γiαi=A+=1,
the roll gap is just in an over-lubricated status; according to

αi=Δ⁢hiRi′
and the calculation formula of the neutral angle γiof each stand,

according to the relationship between the friction coefficient and the oil film thickness: ui=ai+bi·eBi·ξi(in the embodiment, ai=0.0126, bi=0.1416, and Bi=−2.4297), the over-lubricated oil film thickness critical value ξi+of each stand is calculated by the calculation formula:

(f2) calculating the under-lubricated oil film thickness critical value ξi+of each stand is calculated:

it is assumed that when

γiαi=A-=0.6,
the roll gap is just in an under-lubricated status,

according to the relationship between the friction coefficient and the oil film thickness: ui=ai+bi·eBi·ξi, the under-lubricated oil film thickness critical value ξi−of each stand is calculated by the calculation formula

subsequently, in the step (f3), the vibration determination index reference value ξ0iis calculated, wherein

subsequently, in the step (g), the emulsion concentration of each stand is set as Ci={4.2, 4.2, 4.2, 4.2, 4.2} %.

Then, in the step (h), the outlet temperature Tiof the strip steel of each stand is calculated according to the sub-steps shown in theFIG.3.

Subsequently, in the step (h1), the outlet temperature T1of the first stand is calculated as follows:

Subsequently, in the step (h2), i is set to 1.

Subsequently, in the step (h3), the temperature of the first section of strip steel behind the outlet of the f0 stand is set to Ti, 1, i.e., Ti, 1=Ti=172.76° C.

Subsequently, in the step (h4), j is set to 2.

Subsequently, in the step (h5), the relationship between the temperature of the jthsection and the temperature of the j−1thsection satisfies the following equation:

wherein k0is the influence coefficient of the nozzle shape and the spraying angle, and k0=1.

Subsequently, in the step (h6), whether the inequation j<m is established is determined, if yes, then setting j=j+1 and turning to step (h5); if no, turning to step (h7).

Subsequently, in the step (h7), the temperature of the 30th section (when m=30) is obtained via iterative calculation: T1.30=103.32° C.

Subsequently, in the step (h8), the inlet temperature T2Inletof the second stand is calculated as follows: T2Inlet=T1,m=103.32° C.

Subsequently, in the step (h9), the outlet temperature T2of the second stand is calculated as follows:

Subsequently, in the step (h10), whether the inequation i<n is established is determined; if yes, setting i=i+1 and turning to the step (h3); if no, turning to step (h11).

Subsequently, in the step (h11), the outlet temperature of each stand is obtained: Ti={17276, 17802, 186.59, 194.35, 206.33}° C.

Subsequently, in the step (i), the dynamic viscosity η0iof the emulsion in the roll gap of each stand is calculated by equation: η0i=b·exp(−a·Ti) (in the equation, a and b are dynamic viscosity parameters of the lubricant under the atmospheric pressure, wherein a=0.05, b=2.5), η0i={5.39, 5.46, 5.59, 5.69, 5.84} is obtained.

Subsequently, in the step (j), the thickness ξiof the oil film in the roll gap of each stand is calculated by the following calculation formula:

wherein, krgrepresents the coefficient of the strength of the surface longitudinal roughness of the work roll and the strip steel to entrain the lubricant, wherein krg=1.183, Krsrepresents the impression rate, i.e., the ratio of transmitting surface roughness of the work roll to the strip steel, wherein Krs=0.576, and S={0.784, 0.963, 2.101, 2.043, 1.326} um is obtained.

Subsequently, in the step (k), the emulsion concentration comprehensive optimization target function is calculated as follows:

wherein X={Ci} is an optimized variable, and λ=0.5 is a distribution coefficient, and F(X)=0.94 is obtained.

Subsequently, in the step (m), whether the emulsion concentration Ciexceeds the range of the feasible region is determined, if yes, the step (n) is performed; if no, the step (g) is performed.

Subsequently, in the step (n), the optimal emulsion concentration set value Ciy={4.2, 4.2, 4.5, 4.6, 4.3} % is outputted, wherein Ciyis the value of Ciwhen the calculated value of F(X) is minimum in the feasible region.

Finally, during the whole rolling process, the control system of the cold continuous rolling mill set adjusts and controls the emulsion concentration of each stand respectively according to the optimal emulsion concentration set value obtained in the step (n).

To sum up, the technical solution of the invention changes the mode in the prior art that the emulsion in each stand adopts constant concentration control, takes the concentration of the emulsion in each stand as a variable to be optimized, and carries out comprehensive optimization control on the emulsion concentration, thus achieving suppressing the vibration of the rolling mill.

The method of the invention can be widely used in the field of controlling emulsion concentration of the cold continuous rolling mill set.