Comparison of experimental, analytical and simulation results for hot rolling of S275JR quality steel

Abstract

Hot rolling allows the material to be shaped in successive steps in different steps since the material is at a temperature above 0.5Tm which is the recrystallization temperature and gives the possibility of deformation with large deformation rates. In the industry, direct applications show negative effects on time and cost. Practical processes by experimenting can be completed in short periods in some symmetrical profile section products and long periods in some asymmetric profile section products. Finite element method (FEM) can be applied in order to predict the results obtained by simulating the designed calibrations in the computer environment before testing in the rolling mill. In this study, the production of HEA 240 profile in S275JR quality is experimentally made in 21 passes and the geometric dimensions of the first three passes of this structure was compared with 3D FEM analysis results. The comparison results are compatible and high similarity ratio as 95–99.1% was found. Following to this, the analytically calculated dimensions of calibrated IPE 140 profile in S275JR quality was compared by the verified 3D FEM analysis. Considering the first 5 passes of 15 passes for saving time, the simulation and analytical results are in close relationship less than 5% deviation ratio. It is possible to say that this simulation, which has small acceptable differences, has a significant effect on minimizing losses in production processes and achieving production targets.