Design Optimization of Key Structural Parameters for Tension Measuring Rollers in Temper Mill Units
Abstract
:1. Introduction
2. Optimization of Tension Measuring Roller Diameter and Warpage Verification
2.1. Warpage Calculation Model
2.2. Warpage Verification of Steel Strip
2.2.1. Warpage Amount for Different Steel Grades and Thicknesses
2.2.2. Warpage Amount for Different Tensions
2.2.3. Warpage Amount for Different Wrap Angles
2.3. Summary of This Section
3. Optimization of Tension Measuring Roller Sleeve Wall Thickness and Wrap Angle, and Scratch Verification
3.1. Force Analysis of the Tension Measuring Roller
3.2. Scratch Verification of Steel Strip
3.3. Summary of This Section
4. Verification of the Connection Safety of Tension Measuring Roller Sleeve and Shaft End
4.1. Stress and Deformation of Roller Sleeve and Shaft End
4.2. Verification of the Connection Safety
5. Verification by Finite Element Simulation
6. Production Trials of the Unit
7. Conclusions
- (1)
- It was confirmed by this research that the steel strip scratch defects caused by the tension measuring roller in temper rolling are due to relative sliding between the steel strip and the tension measuring roller. The fundamental reason for this is that the driving torque of the steel strip on the tension measuring roller is insufficient to overcome its total rotational resistance torque. The steel strip wrap angle, tension measuring roller sleeve outer diameter, and wall thickness are key structural parameters that influence this torque balance.
- (2)
- The structural parameters of the tension roller were optimized and verified to achieve the ideal warpage, scratching, and connection safety based on theoretical calculations and finite element analysis. By establishing corresponding mechanical models and simulation models, the influence of parameters such as the roller sleeve outer diameter, roller sleeve thickness, and steel strip wrap angle on the amount of steel strip warpage, the driving torque, and the stress on the connection parts was systematically evaluated. In the warpage verification, the results showed that, when the roller sleeve outer diameter was 500 mm, the warpage of the DQ-IF and 590DP steel grades fluctuated from around 1 mm to 1.5 mm, which is far less than 1% of the steel strip length, while 300 mm and 400 mm roller sleeve outer diameters led to warpage as high as 23 mm and 16 mm for some thicknesses, far exceeding the acceptable range. In the scratching verification, by comparing the difference between the driving torque and the total resistance torque, it was found that, under the conditions of a roller sleeve outer diameter of 500 mm and a wrap angle of 30°, when the roller sleeve thickness was 20 mm or 25 mm, the torque difference was positive and retained a certain margin, meeting the safety requirement for no scratching. Finally, comprehensively considering the verification results from all aspects, the optimal solution was determined to be a combination of a roller sleeve outer diameter of 500 mm, a roller sleeve thickness of 20 mm, and a wrap angle of 30°, and this solution satisfies the structural connection safety requirements. In the connection safety verification, the calculation results showed that the relative sliding safety factor met the requirements for both 20 mm and 25 mm roller sleeve thicknesses.
- (3)
- The results of theoretical analysis, finite element simulation, and actual production tests consistently indicated that the optimized tension roller structural parameters can effectively prevent relative sliding between the steel strip and the tension roller, completely eliminating scratch defects on the lower surface of the steel strip. The finite element simulation results show that, when using the optimized parameter combination of a roller sleeve outer diameter of 500 mm, a roller sleeve thickness of 20 mm, and a wrap angle of 30°, the total tangential force (CFSM) on the contact surface between the steel strip and the roller sleeve fluctuates stably around the limit of the maximum static friction force (μ × CFNM), and that there is no situation where the CFSM is consistently greater than μ × CFNM, confirming that no slipping occurred. The actual production tests, after adopting the optimized solution, involved vertical and horizontal inspections on steel strips of multiple steel grades and specifications, and the results showed that scratch defects no longer appeared on the steel strip surfaces, indicating that the scratching problem was completely resolved. The tension roller structural optimization scheme proposed in this study has achieved success in actual industrial applications, indicating that is provides a reliable technical approach to solving the scratching problem in temper rolling.
- (4)
- In the theoretical analysis and simulation modeling process of this study, some parameters were simplified, and the complexity of the actual production environment may have a certain impact on the results. For example, the friction coefficient may change with factors such as the temperature and lubrication state, while it may have been assumed as a constant in this model. Furthermore, this study mainly conducted detailed verification for specific steel grades and specifications. When extending the optimized solution to other steel grades and a wider range of thicknesses, further verification and adaptive adjustments are needed. Future research can consider introducing more complex models to more comprehensively consider various influencing factors in the actual production environment, which would thereby further enhance the universality and robustness of the optimized solution.
Author Contributions
Funding
Data Availability Statement
Conflicts of Interest
References
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Parameter | Existing Value | Optimized Value 1 | Optimized Value 2 |
---|---|---|---|
Roller Sleeve Outer Diameter (mm) | 500 | 400 | 300 |
Roller Sleeve Wall Thickness (mm) | 30 | 25 | 20 |
Steel Strip Wrap Angle (°) | 20 | 25 | 30 |
Steel Strip Code | A | B | C |
---|---|---|---|
Steel Grade | DQ-IF | DQ-IF | CQ |
Steel Strip Specification (mm) | 0.5 × 900 | 0.7 × 1300 | 2.0 × 1600 |
Entry Tension T2 (kN) | 35.28 | 53.51 | 147.39 |
Steel Strip Code | Roller Sleeve Wall Thickness (mm) | Exit Tension T1 (kN) | Radial Load P0 (kN) | Inertial Torque (N·m) | Bearing Seal Resistance Torque (N·m) | Total Resistance Torque (N·m) | Driving Torque (N·m) |
---|---|---|---|---|---|---|---|
A | 20 | 36.5 | 24.1 | 174.4 | 120.5 | 294.9 | 313.2 |
25 | 36.5 | 25.3 | 198.8 | 126.2 | 325.1 | 313.2 | |
30 | 36.5 | 26.4 | 221.6 | 131.9 | 353.5 | 313.2 | |
B | 20 | 55.4 | 30.5 | 174.4 | 152.7 | 327.1 | 475.0 |
25 | 55.4 | 31.7 | 198.8 | 158.4 | 357.3 | 475.0 | |
30 | 55.4 | 32.8 | 221.6 | 164.1 | 385.7 | 475.0 | |
C | 20 | 152.6 | 63.7 | 174.4 | 318.6 | 493.0 | 1308.3 |
25 | 152.6 | 64.9 | 198.8 | 324.4 | 523.2 | 1308.3 | |
30 | 152.6 | 66.0 | 221.6 | 330.0 | 551.7 | 1308.3 |
Steel Strip Code | Roller Sleeve Wall Thickness (mm) | Exit Tension T1 (kN) | Radial Load P0 (kN) | Inertial Torque (N·m) | Bearing Seal Resistance Torque (N·m) | Total Resistance Torque (N·m) | Driving Torque (N·m) |
---|---|---|---|---|---|---|---|
A | 20 | 36.9 | 27.2 | 174.4 | 136.2 | 310.6 | 393.2 |
25 | 36.9 | 28.4 | 198.8 | 141.9 | 340.8 | 393.2 | |
30 | 36.9 | 29.5 | 221.6 | 147.6 | 369.2 | 393.2 | |
B | 20 | 55.9 | 35.3 | 174.4 | 176.5 | 350.9 | 596.3 |
25 | 55.9 | 26.5 | 198.8 | 198.8 | 381.1 | 596.3 | |
30 | 55.9 | 27.6 | 221.6 | 221.6 | 409.6 | 596.3 | |
C | 20 | 154.0 | 76.8 | 174.4 | 384.2 | 558.7 | 1642.5 |
25 | 154.0 | 78.0 | 198.8 | 390.0 | 588.8 | 1642.5 | |
30 | 154.0 | 79.1 | 221.6 | 395.7 | 617.3 | 1642.5 |
Steel Strip Code | Roller Sleeve Wall Thickness (mm) | Exit Tension T1 (kN) | Radial Load P0 (kN) | Inertial Torque (N·m) | Bearing Seal Resistance Torque (N·m) | Total Resistance Torque (N·m) | Driving Torque (N·m) |
---|---|---|---|---|---|---|---|
A | 20 | 37.2 | 30.4 | 174.4 | 151.9 | 326.3 | 473.9 |
25 | 37.2 | 31.5 | 198.8 | 157.6 | 356.5 | 473.9 | |
30 | 37.2 | 32.7 | 221.6 | 163.3 | 384.9 | 473.9 | |
B | 20 | 56.4 | 40.1 | 174.4 | 200.3 | 374.7 | 718.7 |
25 | 56.4 | 41.2 | 198.8 | 206.1 | 404.9 | 718.7 | |
30 | 56.4 | 42.4 | 221.6 | 211.7 | 433.4 | 718.7 | |
C | 20 | 155.3 | 90.0 | 174.4 | 449.8 | 624.3 | 1979.7 |
25 | 155.3 | 91.1 | 198.8 | 455.6 | 654.4 | 1979.7 | |
30 | 155.3 | 92.3 | 221.6 | 461.3 | 682.9 | 1979.7 |
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Zhang, J.; Zhu, S.; Wang, Z.; Zhu, J.; Bai, Z. Design Optimization of Key Structural Parameters for Tension Measuring Rollers in Temper Mill Units. Metals 2025, 15, 593. https://doi.org/10.3390/met15060593
Zhang J, Zhu S, Wang Z, Zhu J, Bai Z. Design Optimization of Key Structural Parameters for Tension Measuring Rollers in Temper Mill Units. Metals. 2025; 15(6):593. https://doi.org/10.3390/met15060593
Chicago/Turabian StyleZhang, Ji, Sihua Zhu, Zhixuan Wang, Jiahao Zhu, and Zhenhua Bai. 2025. "Design Optimization of Key Structural Parameters for Tension Measuring Rollers in Temper Mill Units" Metals 15, no. 6: 593. https://doi.org/10.3390/met15060593
APA StyleZhang, J., Zhu, S., Wang, Z., Zhu, J., & Bai, Z. (2025). Design Optimization of Key Structural Parameters for Tension Measuring Rollers in Temper Mill Units. Metals, 15(6), 593. https://doi.org/10.3390/met15060593