AP14869080 “Development and research of an innovative method of rolling with a macro-shift, which ensures the production of high-quality thick sheet of non-ferrous metals and alloys”

Improving the quality of metal products in the process of pressure treatment remains one of the most urgent tasks of modern engineering. Among the numerous ways to improve the quality of metal products, metal forming methods that implement intensive plastic deformation occupy a special place. These pressure treatment methods do not just improve the initial cast structure of the metal – they are able to grind the initial grain size to a fine-grained state, which gives the metal a significant increase in mechanical characteristics. Therefore, the development of new pressure treatment methods that can significantly increase the level of processing of the source material is an urgent task.

The main idea of the project is the development and research of a new method for rolling non-ferrous metals and alloys, which allows to obtain a high-quality thick sheet with a fine-grained structure and a high level of mechanical properties.

1) Panin Evgeniy Alexandrovich – PhD, Associate Professor, Associate Professor of the Department of Metal Forming, project manager.

Scopus ID: 55903153300  

ResearcherID: B-7581-2015 

https://orcid.org/0000-0001-6830-0630

2) Arbuz Alexander Sergeevich – PhD, АEО «Nazarbayev University», Research Facility Coordinator. Жобаны орындаушы

Scopus ID: 55888544600  

ResearcherID: K-5828-2013  

https://orcid.org/0000-0002-2081-0612

3) Yerzhanov Almas Satybaldyevich – PhD, Associate Professor, Head of the Department of Metallurgy and Materials Science, project executor.

Scopus ID: 56524559600

ResearcherID:  AFL-9951-2022 

https://orcid.org/0000-0002-8990-5919 

4) Kuis Dmitry Valerievich – cts, Associate Professor, Head of the Department of Metallurgy and Materials Science, Belarusian State Technological University, project executor.

Scopus ID: 56769768000

ResearcherID: AAO-9153-2020

5) Tolkushkin Andrey Olegovich – Master’s degree, project executor.

Scopus ID: 57000494500

https://orcid.org/0000-0002-8470-574X 

6) Esbolat Aibol Batyrkhanovich – Master’s degree, lecturer at the Department of Metalworking by Pressure, project executor.

Scopus ID: 57931507900 

ResearcherID: JMQ-0969-2023

7) Krupenkin Ivan Ivanovich – Master’s degree, project executor.

Scopus ID: 57219172987 

Based on the analysis of scientific, technical and patent literature, a new innovative method of thick-sheet rolling in rolls of a new design with the imposition of an asymmetry effect will be developed; with the help of computer finite element modeling, patterns of changing the shape of the workpiece during deformation according to the proposed technology will be established.

In the course of a comprehensive study of the influence of various parameters of the deformation process by the finite element method, patterns of changes in the stress-strain state, energy-force parameters and microstructure evolution will be established, on the basis of which optimal parameters for the successful implementation of the new technology will be determined; analytical dependences will be obtained to determine the contact pressure and rolling force in rolls of a new design; the development of working drawings of rolls of a new design will be carried out, as well as the assembly and testing of a mill with a modified rolling cage for rolling according to the proposed technology.

An experimental batch of blanks formed using the new technology will be obtained; the main patterns of evolution of the microstructure and mechanical properties of copper blanks formed using the new technology from various technological and geometric parameters of the implementation of this process will be established; recommendations for the introduction of the developed deformation technology into production will be developed.

Based on the results of scientific research, 3 articles and (or) reviews will be published in peer-reviewed scientific publications indexed in the Science Citation Index Expanded of the Web of Science database and (or) having a CiteScore percentile in the Scopus database of at least 35 (thirty-five). In addition, one (1) article or review will be published in a peer-reviewed foreign or domestic publication recommended by SHEQAC. The results obtained during the implementation of research on this project will be reported in person or online at several international conferences in countries such as Bulgaria, Belarus and other countries of the far and near abroad.

1 Based on the analysis of scientific, technical and patent literature, a new innovative method of thick-sheet rolling in rolls of a new design with the imposition of an asymmetry effect has been developed

Traditional methods of intensive plastic deformation have proven themselves well in terms of intensive grinding of grains to an ultrafine-grained level. However, they are unsuitable for industrial use and mass production due to the inability to process long blanks and ensure continuous deformation. These problems can be solved by the rolling process. Well-known rolling methods that implement intensive plastic deformation make it possible to obtain high-quality long-length blanks in the form of rods or sheets. However, most of these technologies require either special mill designs (radial shear rolling) or the introduction of additional workpiece processing operations (surface treatment and cryogenic cooling). Various methods of asymmetric rolling provide a high level of deformation, which leads to significant grain crushing. Methods of both velocity asymmetry (with a difference in the speed of rotation of the rolls) and geometric asymmetry (with a difference in the diameters of the rolls) are being actively developed. Rolling in relief rolls is an asymmetric rolling process with uneven metal processing, both in thickness and in width of the workpiece. However, the introduction of an additional coefficient of speed asymmetry led to a significant increase in the level of processing.

2 Using computer finite element modeling, the patterns of changing the shape of the workpiece during deformation according to the proposed technology are established

In this section, using finite element modeling, the shape change of metal during asymmetric rolling in relief rolls was studied. It has been found that in the presence of even a small level of asymmetry in smooth rolls, the workpiece begins to bend in a vertical plane. The presence of a relief section of the workpiece, in which the formed protrusions and recesses act as stiffeners, leads to the fact that after leaving the deformation zone of the relief rolls, the workpiece practically does not bend, maintaining its horizontal trajectory of movement. This effect is observed both in the scheme of geometric asymmetry and in the scheme of velocity asymmetry. This effect makes it possible to introduce asymmetric rolling in relief rolls into the continuous rolling scheme.

3 In the course of a comprehensive study of the influence of various parameters of the deformation process by the finite element method, patterns of changes in the stress-strain state, energy-force parameters and the evolution of the microstructure were established, on the basis of which the optimal parameters for the successful implementation of the new technology were determined 

In this section, finite element modeling of asymmetric rolling in relief rolls is performed in order to study the stress-strain state, energy-force parameters and the evolution of the microstructure. Considering the results of modeling the rolling process in relief rolls with various types of asymmetry, it was revealed that contact asymmetry is the least effective option, whereas kinematic and geometric asymmetries showed good results in metal processing. The final process scheme must be selected based on the technological data of the rolling mill.

Upon further consideration of the variant with geometric asymmetry, the main parameters of the stress-strain state and the deformation force in models with radial and trapezoidal relief were compared. It was found that despite the increased level of stress and effort, the use of trapezoidal relief makes it possible to increase the level of metal processing by almost 5 times compared with the use of radial relief. Therefore, the most effective solution for the implementation of rolling in relief rolls will be the use of trapezoidal relief.

A comparison of technological deformation schemes showed that deformation with 180-degree edging of the workpiece between passes significantly reduces the influence of the asymmetry factor. This is reflected both in the level of equivalent deformation and its height difference, and in the distribution of grain size over the width of the workpiece. Deformation without changing the positioning of the workpiece between the passes has the opposite effect, such a scheme significantly increases the influence of the asymmetry factor. Deformation with a transverse shift of the workpiece for the relief period between passes has the effect of a “golden mean” when the influence of asymmetry takes place, however, the difference in the values of deformation and grain size is not as large as in the previous case.

4 Analytical dependences are obtained for determining the contact pressure and rolling force in rolls of a new design

This section presents the results of theoretical studies of the power parameters of rolling thick-sheet blanks in relief rolls. Empirical dependences were obtained to determine the average rolling pressure and force. When studying pressure, an approach was used to replace the deformation scheme with a flat analog – a broach in trapezoidal forging strikers. The work balance method was used to derive the average pressure equation. In the analysis of the force, the finite element method was used to determine the geometric parameters of the deformation site, followed by the introduction of correction coefficients into well-known formulas from the rolling theory. The obtained dependencies were verified by comparing with the results of computer modeling for three thicknesses of M1 copper alloy blanks: 10 mm, 12.5 mm and 15 mm with a blank width of 400 mm. The comparative analysis showed high convergence of the calculation and modeling results, as well as the possibility of applying the obtained formulas not only for symmetrical rolling or for speed asymmetry, but also in the case of rolling in relief rolls of different diameters.

5 The development of working drawings of rolls of a new design, as well as the assembly and testing of a mill with a modified rolling cage for rolling according to the proposed technology was carried out

Based on the results of computer modeling using the Compass v.21 CAD system, three-dimensional solid-state models of relief rolls were designed using a geometric asymmetry coefficient of 1.5 (diameter of the upper roll 200 mm, diameter of the lower roll 300 mm) for rolling workpieces with a thickness of 10, 12.5, and 15 mm. After manufacturing a set of rolls and installing them in a rolling mill cage, a laboratory experiment was conducted on a lead billet in order to test the technology being developed, as well as verify the data on shape change obtained by computer modeling. A comparison of the geometric parameters of the workpiece after rolling in relief rolls and two subsequent alignment passes in smooth rolls showed that the results of computer modeling have a high level of convergence. At each stage of deformation, the difference in the geometric parameters of the workpiece between the model and the experiment did not exceed 3-5%.

6. An experimental batch of blanks deformed using the new technology of their M1 copper alloy was obtained. The number of deformation cycles (from 1 to 3) was used as the main factor of variation. Templets were prepared from these blanks to study the microstructure, and samples were cut out to study the mechanical properties.

1. A.B. Esbolat, E.A. Panin, A.S. Arbuz, A.B. Naizabekov, S.N. Lezhnev, A.S. Yerzhanov, I.I. Krupenkin, I.E. Volokitina and A.V. Volokitin. Development of Asymmetric Rolling as a Severe Plastic Deformation Method: A Review. Journal of Ultrafine Grained and Nanostructured Materials. 2022. Vol. 55. Iss. 2, Р. 97-111, – https://doi.org/10.22059/jufgnsm.2022.02.02 (Scopus, 15th percentile)

2. A. Esbolat, E. Panin, A. Arbuz, D. Kuis, S. Lezhnev,I. Krupenkin, M. Erpalov. Concepts analysis of asymmetry factor implementation during rolling in relief rolls. Journal of Chemical Technology and Metallurgy, 2022, Vol. 57, Iss. 6, P. 1243-1250, –  https://www.scopus.com/record/display.uri?eid=2-s2.0-85140021756&origin=resultslist (Scopus, 38th percentile)

3. A. Esbolat, E. Panin, A. Arbuz, D. Kuis, A. Naizabekov, S. Lezhnev, A. Yerzhanov, I. Krupenkin, A. Tolkushkin, A. Kawalek, D. Voroshilov. Investigation of force parameters during rolling in relief rolls. Journal of Chemical Technology and Metallurgy, 2023, Vol. 58, Iss. 5, P. 961-968, – https://www.scopus.com/record/display.uri?eid (Scopus, 35th percentile)

4. Лежнев С.Н., Найзабеков А.Б., Панин Е.А., Есболат А.Б. Валки для прокатки толстых листов. Патент РК на полезную модель № 8066 (12.05.2023 бюл №19).

5. Есболат А.Б., Панин Е.А., Арбуз А.С., Куис Д.В., Ержанов А.С. Исследование силовых параметров при прокатке в рельефных валках. Материалы международного симпозиума «Перспективные материалы и технологии», Беларусь, Витебск, 21-25 августа 2023г. – С. 42-44.

6. E. Panin, A. Arbuz, A. Yerzhanov, S. Lezhnev, D. Goldabin, D. Kuis, A. Esbolat. Предпосылки для разработки нового способа толстолистовой прокатки. VIII International scientific conference “Industry 4.0”. 28 June – 01 July, 2023, Varna, Bulgaria, Vol. 1, pp. 70-72.

7. E. Panin, A. Arbuz, A. Yerzhanov, S. Lezhnev, A. Naizabekov, D. Kuis, A. Esbolat. Моделирование процесса прокатки толстого листа в валках различной конструкции. IX International scientific congress “Innovations 2023”. 26–29 June, 2023, Varna, Bulgaria, Vol. 1, pp. 33-35

8. E. Panin, A. Esbolat, A. Arbuz, D. Kuis, A. Naizabekov, S. Lezhnev, A. Yerzhanov, I. Krupenkin, A. Tolkushkin, A. Kawalek, P. Tsyba, Investigation of the Efficiency of Roll Profiles and Technological Schemes of Deformation of Asymmetric Rolling in Relief Rolls of C11000 Copper Alloy by FEM Simulation, Modelling and Simulation in Engineering, 2024, Vol. 2024, –  2486940. https://doi.org/10.1155/2024/2486940 (Scopus, 56th percentile).