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  • Modeling and Simulation Vibrational

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    Renan Do Nascimento Pimentel
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    Modeling and Simulation Vibrational

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    Modeling and Simulation Vibrational

    Direitos autorais:

    © All Rights Reserved
    Baixe no formato PDF ou leia online no Scribd
    Sinalizar o conteúdo como inadequado
    2 visualizações7 páginas

    Modeling and Simulation Vibrational

    Enviado por

    Renan Do Nascimento Pimentel
    Modeling and Simulation Vibrational

    Direitos autorais:

    © All Rights Reserved
    Baixe no formato PDF ou leia online no Scribd
    Sinalizar o conteúdo como inadequado
    de 7
    Proceedings of The th Intemational Conference on Stel Rolling (STEEL ROLLING '98), 1998, Chiba, Japan, The Iron and Steel Institue of Japan FA Rolling Mills Modelling and Simulation of Vibrational Phenomena in Paul A. MEEHAN, W. John EDWARDS and Glen A. WALLACE Industria) Automation Services Ply. Ld, Teralba, NSW, 2284, Australia ABSTRACT ‘The vibratinal phenomenon known as chatter is investigated using mathematical models to analyse and simulate its ‘ccutrence in roting mils. Models for torsional, third ara fith octave chatter are presented and discussed, & stabity erteron {or the erticalroling speed is developed for third octave chatter in tems of known roling parameters, This cretion provides a Useful practical design tool forthe avoidance of third octave chatter. An investigaion ofthe effct of various mil parameters on the occurrence of third octave chatter is performed. tn general, the results presented inthis paper, coreate wall with practical ‘observation anc provide significant new ineights into methogs of avoidance of chater instability KEY WORDS: chatter vibration: numerical simulation; tied octave: ith octave, INTRODUCTION Over the past century, significant advances in technology have allowed rolling mills to operate at relatively high speeds to increase productivity and efficiency. However, these speed increases have often been accompanied by mechanical vibrations, generally referred to a5 chater, which cause periodic, ransverse, bands of light and dark appearance across the stip. In some eases, a matching thickness variation is associated with the “chatter bands”. This phenomenon is highly undesirable. Not only must the affected product be rejected, but strip beaks may lead to damage inthe mill equipment. Usuell ithas been found that as mill speeds ate increased the vibrations become more severe. Thus, at present, the only reliable remedy for chatter is to reduce the operating speed of the rolling mill which adversely affects mill productivity, Generally, three distinet types of mill chater, have been identified, namely: * Torsional chatter, which causes significant chatter bands across the strip and small thickness fluctuations, occurs in the 5-25 Hz range. This is ‘often referred to as rumble or shudder, reflecting the Jow frequency range in relation to the audible range. ‘The small variations in thickness may cause uctuations in surface reflectivity which are aesthetically unacceptable. ‘Third octave mode chatter, which produces large thickness variations and strip rupture lies inthe 125- 240 Hz range. This form of chatter is found to occur mostly in high speed tandem cold mills rolling thin strip products. It is characterised by a sudden ‘occurrence (usually <5 seconds) and thus appears to be selexcited as opposed to externally excited + Fifth octave mode chatter occurs in the range 500- 800 Hz and results in transverse banding of the backup and work rolls and matching transverse surface marking ofthe strip. To cure the problem, an unscheduled backup roll change is often required 166 There is experimental evidence to suggest that although there is negligible thickness variation, the strip is not flat and has a periodic corrugated waveform, These strip marks (or comugations) are sull visible after the strip has been temper rolled and painted. Of the three types of chatter, third octave made chatter is the most destructive and has the most detrimental effects on mill productivity due tothe lower rolling speeds required to avoid the phenomena, However fifth octave chatter seems to be more prevalent ia rolling mills and is of increasing concern as customers are demanding better surface quality It seems likely that with better knowledge of the chatter mechanism, more effective strategies may be formulated. If accurate chatter simulation models can be developed they will provide an invaluable tool for the investigation of alternative methods for suppressing the phenomena. The present paper describes recent research into the modelling, analysis and simulation of chatter. Results pertaining to torsional, third and fifth octave chatter will be dealt with in tum. The mathematical symbols and notation used are defined in the nomenclature section 2 TORSIONAL CHATTER Torsional vibration involves the mill components, shown in Fig. 1. The rolls undergo periodic angular speed variations, while the drive spindles act as torsional springs. The strip also acts as a spring in this system, but under most conditions its influence is not significant compared to that of the spindles. ‘When the top and bottom work rolls are out of phase the response of the rolling torque to an asymmetrical rolling condition needs to be considered in the analysis, In the past, this aspect has usually been neglected. Recent research") has shown that differential roll speeds lead to a reduced roll force and increased torque. Fig. 1 Components ofa 4-High Mill Involved in Torsional Vibration Early experimental work by Moller and Hoggart®! identified the main parameters involved in the torsional vibration of @ mill rolling aluminium strip. A relatively simple calculation of the natural torsional vibration frequency of an experimental 2-high mill agreed closely with their observations. For a typical mill, the natural frequency 0, is givenby: fai 283 ~) Sad (On +”°Q,) 2 where (Q,. = torsionalstifines ofthe drive shaft Op. = torsionalstiffess ofthe spindls/couplings Jj =momentofineriaof the rolls and spindles J, =momentof inertiaof the motor armatureand diveshat and n= gearbox ratio (motor:roll speed). Fora 4-high mill, the moments of inertia of both work and backup rolls need to be included in the term J. tis ‘often the case that the torsional stiffness of the motor ‘gearbox shaft is much higher than that of the roll drive spindles, Furthermore, if the referred motor inertia n° J', is significantly greater than the effective rotl inertia, the expression collapses to: 2 2) 5 @ Some occurrences of sustained torsional vibration have been attributed to speed control systems. Badly tuned control loops or noisy speed feedback signals from tachometers have been reported to cause instability. Gears in the drive train have also been identified as the source of vibration in some cases. 3. THIRD OCTAVE CHATTER It is generally accepted that third octave chatter is a self-excited phenomena. Insight into the dynamics of this mode of chatter have been provided by several authors!” From these analyses it is clear that the phenomenon has a relationship with interstand tension ‘STEEL ROLLING °98, Chibe, ISIS fluctuations in the strip and the inherent vertical dynamics of the roll stack. In particular, Paton and Critchley”? confirmed experimentally that there is @ 90 degree phase shift between the workroll positions and the stand eniry tension oscillations at the chatter frequency. —Thusty" and Tamiya showed that instability could arise if the tension was out of phase with the roll deflections but neglected forward slip variations, Using a different approach, Roberts derives instability criteria from simplified roll force equations that predict chatter due to excessive entry tension and inadequate roll-bite lubricity, For a more complete model it appears that the incorporation of tension effects, slip interaction and roll stack dynamics is required with minimal assumptions about the dynamics of each mechanism. Chefneux et al! amongst others, have developed such models to numerically simulate chatter, however, no major insights were gained pertaining to the exact condition for instability due to the complexity of the models. More recently, Jepsen and Kneppe" have used simplified models to obtain qualitative conditions for third octave chatter in a tandem mill however the significant interaction due to slip was not included, 31 Dynamic Modelling A key aim of this research is to develop an explicit criterion for predicting the rolling speed at which chatter instability will occur in terms of the rolling model parameters. For the purpose of investigating third octave chatter, the vertical roll stack dynamics may be modelled by utilising the discrete spring-mass-damper system depicted in Fig, 2. Note that the work roll - strip flattening stiffness k,.is included explicitly, By assuming that the roll stack is vertically symmetrical about the stand passline, the relative movement between the backup chocks and rolls is small and the damping is low, the system shown in Fig. 2 reduces to a 4 degree of freedom system as described in Fig. 3. This figure illustrates each of the modal roll displacements and natural frequencies of the system. I may be seen from Fig. 3 that only modes 2 and 4 will be excited by roll force variations in the strip and cause significant thickness variations. Only mode 2 has a natural frequency within the range of observed third ‘octave chatter. Modes 3 and 4 could be in the fifth octave chatter range. For chatter to occur, the vertical oscillations of the roll stack must be excited. The ‘most likely mechanism for Fig. 2 Dynamic Model of Four High Roll 167 = STEEL ROLLING "98, Chiba, ISI Fig. 3 Mode Shapes of Vertical Motion of Four High Roll Stack this in third octave chatter is via strip deformation interactions which incorporate interstand dynamics. Practical observations!” suggest that tension oscillations in the strip become large during chatter and have a relationship with the vertical motion of the roll stack ‘due to roll force induced variations. Tlusty et al") and Pawelski et al.” also indicate that the roll bite geometry may vary ftom conventional models when the ratio of the chatter vibration period is of the same order as the rollgap transit time. To understand the relationship between the roll force, vertical roll vibrations and interstand tension dynamics it is instructive to inspect the block diagram shown in Fig. 4 and to consider the consequence of a perturbation in the gap between the work rolls of stand i. Hee Fig. 4 Simplified Block Diagram Illustrating Rollstack Vibration and Interstand Tension Interaction Firstly, the exit thickness will increase. To ensure continuity of mass flow, the strip entry speed will have to inerease by the same fraction. This produces a speed ‘mismatch with the strip exiting the previous stand, and the interstand tension force will start to increase as would be the case if the interstand strip was a static elastie spring with a relative movement between its ends. An increasing tension will reduce the roll force and lead to a reduction in strip exit thickness by moving the work and backup rolls, partially cancelling the effect of the initial gap perturbation. The tension increase also induces slip changes of opposite sign in the stands at each end of the interstand gap. The tension response will stabilise at a finite value which reflects the combined influence of the thickness and slip interactions. The response of the tension to a change in roll gap position may be shown to be equivalent to a first order linear system with a time constant s, given by the equation: L ye ey vwen|(r'e,)_ laren) ‘The crucial issue here is that the time constant +, is inversely proportional to mill speed. This means that at ow speed the time constant r, is large enough to inhibit significant tension fluctuations at the natural frequency of the roll stack. As the mill speed increases, the time constant reduces allowing tension interaction to occur, This speed dependent interaction will contribute a component of negative damping to the system. Under certain conditions, this may be sufficient to cancel the inherent positive damping in the roll stack, and sustained vibration, or chatter, will then ensue. ‘The chatter models and mechanism described above were investigated via stability analysis and numerical simulation. In the following, a brief description of these methods and results is provided, 32 Stability Criterion The equations of motion for the mill dynamic models described may be solved algebraically to derive a relationship between the primary variables involved in the chatter mechanism. Classical stability analysis techniques can then be employed to obtain an explicit expression for the critical rolling speed. Details of the

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