Development Of The Integrated Simulation System Of Multi-model H-beams Rolling

H-beams, structural steel members with an H-shaped cross-section, have high second moments of area, which allow them to be very stiff in respect to their cross-sectional area. Because of their excellent mechanical properties and cost-effective economic benefits, H-beams are widely used in the construction industry and civil engineering. However, the hot rolling of H-beam is a highly non-linear plastic deformation process under the high temperature and high pressure, and the internal information for work-piece and deformable roller in rolled process can not be obtained in real time because of the hot environment. In order to solve the above problems, an finite element simulation system for hot rolled mutli-model H-beam is developed in this paper. Through the simulation system, hot rolled mutli-model H-beam can be achieved automatically, which is significant to the majorization of hot rolled process and development of new H-beam.This dissertation focuses on the finite element method (FEM) using in computer simulations of hot rolling processes of H-beams. Based on the Abaqus, an elastic-plastic finite element model coupled thermal mechanical is founded to simulate the whole hot rolled process, including hi-pressure water descaling, breakdown, universal rolling and cooling. In the FEM simulation of rolling processes, the final shape of the product can be drastically different from the original shape, so that the mesh that is optimal for the original product geometry can become unsuitable in later stages of the process when large material deformation leads to severe element distortion and entanglement. Thus, it is necessary to remesh:to create a new mesh of better quality, and to map the solution from an old, deformed mesh to the new mesh, so that the analysis can continue.In this dissertation, the integrated simulation system of multi-model H-beams rolling is developed by customized applications and of the secondary development for Abaqus, in which the remeshing and mapping scripts, pre-processing scripts and post-processing scripts written by Python are embedded. The manipulation of the Scientific and Technology Development Program of Shandong Province (2010GGX10421) simulation system has been facilitated through customized user’s interfaces and GUIs.The use of simulation system throughout the product life-cycle, especially at the earlier concept and design stages, has the potential of providing substantial benefits. The simulation system can be used in the H-beam manufacture process to predict the performance of an existing or planned manufacture process system. These benefits range from direct cost issues such as reduced trial-manufacture and shorter time-to-market, to better performing products and higher margins.