Numerical Simulation of the Effect of Process Parameters on Pass Filling Degree in F-Section Steel Finishing Rolling Process

Due to the asymmetry of pass profiles, F-section steel is prone to defects such as overfilling, underfilling, and twisting during production, which significantly deteriorates the dimensional accuracy, mechanical properties, and surface quality of products. To mitigate the occurrence of such defects, this study established a thermo-mechanical coupled three-dimensional finite element model for the finishing rolling process of F-section steel using ABAQUS 2022 incorporating the actual operating conditions of the steel plant’s production line. By analyzing the stress–strain fields of each pass, it was found that the maximum deformation of the rolled piece is concentrated at the junctions of the inner leg with the flange, the inner leg with the web, and the outer leg with the web. Additionally, underfilling was observed at the legs and flanges of the pass in each rolling sequence. Based on these findings, an in-depth analysis was conducted on the effects of friction coefficient, tension configuration, rolling temperature, and web reduction on pass filling degree. Conditions of low friction, small reduction, and high temperature facilitate the smooth filling of metal in the leg cavity; in contrast, conditions of high friction, large reduction, and low temperature promote the filling of surface metal and an increase in spread. Maintaining a low-tension state is a common favorable condition for improving the pass filling degree of both the legs and the surface. When the friction coefficient is 0.2, tension is 0, rolling temperature is 1040 °C, and web reduction is 4 mm, the pass filling degrees of the inner and outer legs reach their maximum values of 99.88% and 99.16%, respectively. When the friction coefficient is 0.4, tension is 0, rolling temperature is 1010 °C, and web reduction is 4 mm, the pass filling degrees of the upper and lower surfaces are maximized, reaching 98.95% and 98.22%, respectively. These findings provide data support and theoretical guidance for addressing defects encountered in F-section steel production.