RSM Solutions Using Finite Element Modelling

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RSM Solutions Using Finite Element Modelling
Corus Consulting Limited, Teesside Technology
Centre, P.O. Box 11, Grangetown,
Middlesbrough, Teesside TS6 6UB U.K. Telephone
44 (0)1642 467144 Fax [phone]
460321 E-mail colin.notman_at_corusgroup.com
Swinden and Teesside Technology Centres have over
many years developed expertise in modelling of
Roller Straightening Machines (RSM). Finite
Element models using the commercial package
ABAQUS have been developed to investigate and
optimise Roller straightening of a range of
products covering rail, structural sections,
special sections, billet and plate.
Residual stress is an increasingly important
design parameter for customers of many long
products but particularly rail. Finite Element
models have been used as an aid to ensure the
delivered product consistently meets the customer
requirements for residual stress. This type of
analysis is particularly valuable where the
parameter of interest e.g. residual stress, is
difficult to measure accurately and therefore the
effect of RSM changes are difficult to assess.
Billet Straightening
Solidification studies, bulging and
strain calculations
Strain ()
1
0.9
0.8
0.7
0.6
0.5
0.4
Residual Stress Distribution in half rail model
0.3
0.2
BULGING STRAIN
MISALIGNMENT STRAIN
0.1
0
0
100
600
Practical solutions to problems such as reducing
web stretch and optimising penetration settings
for robust straightening have been achieved
without the need to resort to extensive plant
trials. Improving the performance of the roller
straightening process involves analysis of a
range of set-up parameters often specific to a
product and plant. A wide range of cases can be
compared relatively quickly to find the best
compromise for a specific application.
Increasing the size range of a roll straightener
may place significantly increased loads on the
machine. Rolling loads can be predicted for a new
product size or section enabling the risk of
machine damage to be assessed. The extent of
plastic deformation may also be predicted to
determine if sufficient is available to remove
the worst out-of-straightness and residual stress.

• Potential Benefits of Finite Element Analysis of
  Roller Straightening
• Greater consistency and increased understanding
  of the process.
•  Increased productivity and reduced re-work.
• Increasing the range of sizes that can be roller
  straightened

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