An AISI/DOE Technology

Hot Strip Mill Model

Introduction
The American Iron and Steel Institute (AISI), in conjunction with the Department of Energy (DOE) and several North American steel companies, funded the development of a microstructure evolution and mechanical properties model. INTEG process group, inc. undertook the task of commercializing the technology developed by the University of British Columbia (UBC) and the National Institute of Standards and Technology (NIST). With the support of the AISI, DOE and five North American steel companies (Dofasco, IPSCO, Stelco, US Steel, Weirton Steel), INTEG continues to upgrade, enhance and validate the model referred to as the AISI Hot Strip Mill Model (HSMM). INTEG has evolved the HSMM into a user-friendly, accurate and valuable tool. The user can easily set-up their mill configuration, including number of reheat furnaces, roughing mill stands, heat retention equipment, finishing mill stands, run out table cooling system and mill exit area. The model can handle both strip and plate and can be configured for reversing mills, continuous mills, tandem mills or Steckel mills utilizing a coiler or cooling bed. A variety of steel grades can be handled with the included material characteristics for basic carbon grades, HSLA grades and Interstitial Free grades. Dual phase steels are being added. The HSMM can be utilized for conducting what-if analysis and detailed process analysis for any of the following parameters: Mechanics of Rolling o Temperatures radiation, water loss, work roll conduction, mechanical working o Rolling Loads rolling forces (flow stress), rolling torques, motor current, motor power o Roll Bite Parameters draft, percent reduction, bite angle, roll bite lubrication o Limits edger buckling, bite angle o Quality strip profile and flatness (shape) Microstructure/Mechanical Properties o Transformation, grain size, precipitation o Yield Strength, Tensile Strength, Elongation

The HSMM uses a series of physical models to calculate both thermal-mechanical and microstructure evolution. The model can be run in both single-node and multiple-node modes. The single-node mode is used for rapid calculation and verification with plant data. The multiple-node mode uses finite

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difference calculations for detailed analysis and study. The microstructure model calculates metadynamic and static recrystallization, austenite grain growth, precipitation, phase transformation and ferritic grain size. After calculating the final temperature run down for the coiler or cooling bed, the final mechanical properties including Yield Strength (YS) and Tensile Strength (TS) are determined. The enhanced HSMM was validated using a variety of samples from several steel companies. Excellent agreement was obtained for YS and TS with final ferrite grain size coming in within acceptable standards of error given the natural error induced with the measurement of grain size.

Applications
The Hot Strip Mill Model can be used for a variety of applications. Current users have utilized the HSMM to study mill configurations, rolling schedules, and process parameters to gain detailed insight into their operations not normally available with their current models and control systems (such as temperature distribution, transformation start temperatures and final mechanical properties). Applications for the model include: Development and optimization of rolling practices Comparative analysis of various mill configurations and upgrade programs Overall facility production capability analysis for a given product mix Product development Evaluation of relationships among process variables such as speed, temperature, retained strain, and mechanical properties Conducting a sensitivity analysis by varying one parameter to determine its impact on other parameters

New Features
Based upon feedback from current users and the requirements needed for the steel industry of the future, HSMM version 6.1 was recently released and contains new features that expand its functionality and flexibility. The key enhancements include: Low Coiling Temperatures the run out table model has been enhanced so that coiling temperatures down to 150 - 200C can be accurately modeled for next generation steels. Grade Builder allows the user to add and configure a new grade of steel by adjusting the model coefficients and/or selecting the algorithm to be used (including their own). Flow Stress Tuning a built-in tool that allows the flow stress equations to be tuned to match mill data, improving the accuracy and expanding the range of these equations. Resistance to Deformation Method Setup a built-in tool for simplifying the calculation of the coefficients for the Resistance to Deformation Method using data entered in the rolling schedules.

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Strip Profile and Flatness calculations added to increase the functionality and value of the HSMM for validating the quality of the rolling schedule and the mechanics of rolling. Database Conversion Utility allows HSMM projects developed with previous versions of the model to be converted easily and accurately for use with the latest release (now and in the future).

Support and Future Development

The HSMM is continuously being enhanced. Work is currently in progress to expand the methods utilized for the microstructure calculations to allow the model to handle additional grades of steel, including Advanced High Strength Steels (dual phase, TRIP, API). The HSMM is sold by license per PC and includes the first year of upgrades and support. After the first year, an annual support agreement is available. Phone, e-mail and fax support is provided by INTEGs staff in Wexford, PA USA. A multiple day training class at INTEGs office is provided with the initial acquisition of the model. Additional classes are available on a regular basis at INTEGs office or at the users facility for an additional fee.

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Overview
The HSMM model performs a variety of calculations to simulate the physical process of rolling steel in a hot strip mill. To model the various mechanical and thermodynamic processes during hot rolling, these calculations rely on equations from the basic principles of physics and on equations developed from theories of rolling mill researchers. In order to properly implement the calculations, an integrated model is provided that includes a user-friendly interface for set-up, configuration, implementation and viewing results. The HSMM contains a completely linked model that allows the user to simulate the processing of the steel from reheat furnace dropout to the coiler or cooling bed. The models tracking program tracks the head, middle and tail points along the length of the piece, modeling each point as it progresses through the mill. The temperature evolution, rolling forces, microstructure changes and final mechanical properties are all calculated for each of the three points.

User Inteface

Microstructure Evolution & Mechanical Properties

Tracking

Rolling Mill Thermal-Mechanical

Run Out Table Thermal-Mechanical

Calculation Points
Tail Middle Head

User Interface
The HSMM utilizes a user-friendly interface allowing each mill to be accurately configured, each rolling schedule to be set-up in detail, each grade of steel to be accurately characterized and the final results to be viewed, charted, reported and exported, as needed. The user interface can be divided into the following main areas: Mill Configuration Grade Calibration Coefficients and Model Selection Rolling Schedule Set-up and Model Results Grade Builder Data Exporting Reporting
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Mill Configuration The Mill Configuration Screen allows the user to set-up the rolling mill to be used in the modeling process. A dynamically generated, scaled picture of the mill is displayed along the bottom while the user configures the following stations: Furnace Area o Conventional Reheat Furnace o Tunnel Furnace Roughing Area o Continuous Rougher o Reversing Rougher o Edgers, Water Sprays and Shears Heat Retention Area o Coil Box o Heat Retention Covers Finishing Area o Tandem Mill o Steckel Mill o Edgers, Water Sprays and Shears Runout Table Cooling Area o Laminar Sprays o Water Walls Mill Exit Area o Coiler o Cooling Bed

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Grade Calibration Coefficients and Model Selection The Grade Calibration Coefficients and Model Selection screen allows the user to tune the model for each grade of steel being simulated through the rolling mill. During the overall project set-up, the user selects a specific set of calibration coefficients to be used for the grade of steel being processed via a specific rolling mill schedule. The user also has the option to select the force model method. A minimal number of calibration coefficients are available for tuning the models to match mill data.

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Rolling Schedule Set-up and Model Results The Rolling Schedule Set-up and Model Results screen is used to enter the rolling schedule of the piece being modeled and to view the results of the single node and multiple node calculations. The screen allows the user to input and view the following: Initial Data Pass Data Speed/Time Shape Temperature Data Rolling Parameters Microstructure Run Out Table Charts Summary Results

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Models
The variety of models used by the HSMM to calculate the temperatures, forces, microstructure and final mechanical properties of the piece being modeled and can be divided into two main areas: 1. Thermal-mechanical The thermal-mechanical calculations of the rolling mill process cover each stage of rolling from the slab dropping out of the reheat/tunnel furnace until the finished product is coiled in the up/down coiler or delivered to the cooling bed. These calculations include the following: Times and speeds during material transfer and rolling Material temperature evolution Roll bite parameters flow stress, strain, strain rate, rolling force Motor torques, powers, and load ratios Production rates Shape

2. Microstructure The microstructure evolution calculations of the rolled material start from the time the slab drops out of the reheat/tunnel furnace and continues until the finished product reaches its final processing temperature, at which time its final mechanical properties are calculated. These calculations include the following: Recrystallization Austenite grain growth Precipitation Phase transformation Ferritic grain size Yield strength Tensile strength Elongation

The models can be run in single node or multiple node modes. The single node and multiple node models are completely independent of one another and can be tuned separately.
Single Node Multiple Node

The single node calculations look at the steel strip as one, throughthickness node. Mechanical property, force and microstructure calculations are provided for an average calculation. The multiple node calculations model the steel strip as a series of 101 nodes through the steel thickness and 10 nodes through each scale layer. Mechanical property, force and temperature calculations provide a distribution of these values throughout the piece.
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Thru Full Slab Thickness

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Thermal-Mechanical Models
To accurately calculate temperature changes, the thermal-mechanical model closely simulates the movements of the work piece through the mill with its configured distances between mill stations (stands or other equipment) and station speed limitations. This requires that speed profiles including acceleration and deceleration be calculated for material movement across tables and during continuous and reversing passes. Additionally, having these accurate time calculations provides the ability to perform accurate production studies. Transfer Table Times and Speeds The travel time for the work piece across a transfer table between two mill stations depends on the following: the speed profile as the piece leaves the first station, the top speed of the piece while free from the two stations, and the speed profile for the piece entering the second station. The top speed of the piece across the table depends on whether the table is long enough for the piece to accelerate to the desired maximum table speed and decelerate in time for the next mill station. The transfer times for the head, middle, and tail points on the work piece are calculated independently as they depend on different portions of the mill station speed profiles. An example speed profile for the head, middle and tail points of the work piece across a transfer table for the calculation of radiation time between stands is shown below.
Top Table Speed Stand 1 Rolling Speed Stand 2 Rolling Speed

Head Out of Stand 1

Middle out of Stand 1

Tail out of Stand 1

Head into Stand 2

Middle into Stand 2

Tail int o Stand 2

Rolling Pass Times and Speeds During reversing passes for roughing stands and Steckel mill stands, each time interval of the speed profile is calculated to determine total pass time and the total rolling time. The pass time is the time interval from the start of the current pass at the instant the piece begins moving to the roll bite until the piece begins moving for the start of the next pass. Pass time includes the delay time between passes. The rolling time is the time that the material is in the roll bite.
Top Speed Tailout Speed Thread Speed

t1

t2

t3

t4

t5

t6

t7

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Temperature Evolution Calculations To support the mechanical parameter and microstructure evolution calculations, an accurate temperature evolution of the work piece through the rolling process is calculated and maintained using the single node and multiple node methods. Both methods calculate and maintain temperatures for the head, middle, and tail of the work piece. Single Node The single node method determines the entry and exit temperature at each equipment station location in the hot mill. From the exit of one station to the entry of the next, the work piece experiences heat losses due to radiation and also to water cooling if any type of descale or cooling header exists. From the entry of the roll bite to the exit of the roll bite, the work piece deforms between the work rolls and experiences a heat loss from contact with the water-cooled work rolls and a heat gain from the energy required to deform it. The resulting average temperature is then fed into the microstructure evolution calculations.

Multiple Node The multiple node method calculates temperature changes of the work piece by dividing all time (time between stands, time in water header contact, and time in roll bite contact) into slices. For each time slice, the effect of either radiation, water cooling, or roll contact is independently applied to the top and bottom material surfaces and the temperature change by heat diffusion between layers is also calculated. This implicit finite difference method produces a temperature distribution profile through the layers that is input into the microstructure evolution calculations.

Time Slices

1 2

Layers

Finite Difference Nodes in Time Slices and Thickness Layers

Finite Difference Time Slices in Roll Bite

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Roll Bite Parameter Calculations For a given rolling pass, there are several parameters that are calculated that relate to the roll bite and its geometry: draft, percent reduction, bite angle, deformed roll radius, contact length, geometric aspect ratio, material resistance to deformation (flow stress), and roll separating force. These parameters apply to both horizontal and vertical (edger) stands. The roll bite model selected by the user determines the calculated roll separating force. If a flow stress model is selected, the material flow stress is calculated and the rolling force is then determined from the flow stress, material width, contact length, and a geometrical factor using Sims force model. Adjustments are made to the force calculation for non-homogeneous compression that occurs during rolling in the early passes when the slab is its thickest. Calculated values for percent reduction, bite angle, and roll separating force are compared with the maximum limits for the mill stand. All over-limit conditions will be indicated to the HSMM user. Torque, Power, and Load Ratio Calculations The HSMM calculates motor overloading as a load ratio of the actual power required for rolling divided by the motors rated power. Each time interval in the pass speed profile has a calculated load ratio that is compared with the motors absolute load ratio limit. If the maximum load ratio for the motor is exceeded, the HSMM may be able to calculate a lower acceleration rate or rolling speed that reduces the calculated load ratio below the limit. Any power or torque calculation that exceeds the motors limits is indicated to the HSMM user. From the speed profile times and load ratios, an RMS cycle time is calculated for the rolling of the work piece. If this value exceeds the value of absolute cycle time, the difference is the additional rest time required for motor cooling Production Rate Calculations From the calculated rolling and pass times in the roughing mill, finishing mill, and coiler, the production rates for each group of coupled stations is calculated. For multiple-pass stations, the production rate calculation includes all passes. Both actual production rates and RMS production rates are calculated. The RMS production rates include any additional delay time required for motor cooling. The rated production rates of the reheat furnaces are proportioned by the hearth coverage in the furnaces (slab length over the furnace width). The mill area with the lowest RMS production rate is the mill bottleneck that limits the overall production on the mill for the current product.

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Roll Bite The roll bite area is one of the most critical areas for calculating proper temperatures, forces and microstructure evolution. The piece is subjected to various strains over a range of thicknesses and for a variety of material types (grades of steel). The HSMM allows the user to select one of four methods for calculating the flow stresses observed in the roll bite. The flow stress methods available include: Resistance to deformation NIST Flow Stress Shida Flow Stress Medina Flow Stress
Roll Bite Calculations

Resistance to Deformation The HSMM features an enhancement that allows the user calibrate the flow stress models. The flow stress models consist of methodologies that are based on physical principles (NIST, Shida and Medina) or that use plant historical data (Resistance to Deformation). The tool for the Resistance to Deformation method allows the user to utilize plant data that is entered into the rolling schedules to calculate the required coefficients for this method. The tool for the physical based models allows the user to calibrate these equations with the same plant data.
Select Method Resistance to Deformation

Plot of the Resultant Curve and Data

Coefficients Automatically Calculated

Select which Schedules to Use

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Flow Stress The following graphic displays the tool for the Flow Stress Methods that are based on physical principles. This tool allows the user to have tuning coefficients automatically developed and utilized based on actual plant data for temperatures and forces.
Select Method Flow Stress

Automatically calculates coefficients to improve results

The NIST flow stress calculation utilizes a series of equations developed by the National Institute of Standards and Technology. The NIST equations are dependent on temperature, austenite grain size, strain, and strain rate with associated coefficients that have been developed for each steel grade. The Shida1 flow stress calculations define the flow stress of steels during hot plastic deformation as a function of carbon content, temperature, strain and strain rate. This method for flow stress calculation can be used as an alternative to the NIST NIST Flow Stress Equations method, which was provide with the original HSMM grades, allowing the user to observer the effects of a wider range of chemical grades. This method is good for plain carbon steels. The Medina2 flow stress calculations define the flow stress curves as a function of temperature, strain, strain rate, austenite grain size and chemical composition. This method for flow stress calculation can be used as an alternative to the NIST method, which was provide with the original HSMM grades,
Shida S., Effect of Carbon Content, Temperature and Strain Rate on Compressive Flow Stress of Carbon Steel, Hitachi Res. Lab. Report, 1974, 1-9 2 Medina S.F. and C.A. Hernandez, General Expression of the Zener-Hollomon Parameter as a Function of the Chemical Composition of Low Alloy and Microalloyed Steels, Acta Mater. Vol. 44, No. 1, pp. 137-148, 1996 HSMM v6.1 Overview Release 2.0 13 May 2004
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allowing the user to observer the effects of a wider range of chemical grades. This method is good for microalloyed steels. Run Out Table The run out table area is a critical area for calculating proper temperatures and microstructure evolution. The ROT is the processing area where the austenite to ferrite transformation and precipitation take place (in most cases) influencing the final microstructure and mechanical properties. Temperatures, microstructure evolution and mechanical properties are calculated for both the single node and multiple node models. For the multiple node model the HSMM utilizes a method to dynamically calculate the heat transfer coefficients for the surface nodes. One of the most complicated areas to model is the heat transfer occurring during the time the steel strip is moving down the run out table through the water sprays. As part of the HSMM development done by UBC, a methodology was developed for automatically calculating the heat transfer coefficients (HTC) for the strip surface, as the point being modeled moves down the run out table, and to integrate the temperature calculation with the microstructure-property model3. This method calculates an HTC based on being located in one of six different zones (0-5) relevant to each water spray. Several zones have been defined covering the time when there is no water on the strip (radiation zones 0,5), when the strip is directly under the water spray (impingement zone zones 2,3) and when there is water on the strip (zones 1,4). An adjustment to the HTC in zone 4 is also dynamically calculated that takes into consideration the gradual drop off in heat transfer capabilities of the pooled water on the strip.

Zone 0

Zone 1 Counter Current Flow

Z-2

Z-3

Zone 4

Zone 5

Radiation

Impingement Zone

Parallel Flow

Radiation

Militzer M., Microstructure Engineering of Hot-Rolled Steel Strip, The Brimacombe Memorial Symposium, pp. 695-705, October 2000 HSMM v6.1 Overview Release 2.0 14 May 2004

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Low Coiling Temperatures The HSMM features and enhancement that allows the temperature model on the run out table (ROT) to handle low coiling temperatures down to approximately 150-200C. These lower coiling temperatures go well below the typical coiling temperature of 550-700C and are needed for products such as advanced high strength steels, including dual phase steel produced on a hot mill. The chart below shows the time-temperature path on the ROT for a coil being simulated on the HSMM that had been coiled around 150C. This coil displays a typical path for a dual phase steel where the strip is cooled to an intermediary temperature, held for a few seconds and then cooled extensively to achieve the low coiling temperature.

The HSMM achieves these low coiling temperatures through the addition of the Leidenfrost effect into the models boiling curves. A typical boiling curve indicates how water, when heated, passes through nucleate boiling, transition boiling and finally into film boiling phases. These phases are a function of the strip temperature and the rate of bubble creation as the water boils. At some point, the rate of creation of bubbles is so great that an actual vapor barrier is created, slowing the transfer of heat between the steel and cooling water. Johann Gottlob Leidenfrost did extensive investigation into how a drop of water is long lived when deposited on metal that is much hotter than the boiling temperature of water. This Leidenfrost effect has been integrated into the HSMM, so that at lower strip temperatures, the rapid transfer of heat to the cooling water can be observed.

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Strip Profile and Flatness Calculations have been added to HSMM to display approximate values for strip profile as determined by the loaded roll gap and any applied work roll bending force. The model also calculates the differential elongation across the strip width caused by a change in strip profile during a pass reduction. If the differential elongation exceeds a known flatness dead band, the model indicates that the strip has either a center buckle or wavy edges.

Strip Shape

Center Buckle Limit

Edge Wave Limit

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Microstructure Models
In combination with the temperature and deformation models, one of the main objectives of the HSMM is to accurately predict the microstructure evolution (and subsequent mechanical properties) for the hot rolling of steel. This is achieved by addressing the key metallurgical features affecting the desired properties of the hot-rolled steel. The processing of steel in a hot strip mill can be subdivided into three principle stages: reheating, rolling (in both the roughing and finishing mill), and cooling (water cooling on the run-out table and natural cooling after coiling). The metallurgical phenomena, which are calculated by the HSMM, are summarized below. Process Step Rolling Metallurgical Phenomena Recrystallization Austenite Grain Growth Precipitation Austenite Decomposition Precipitation

Cooling

The HSMM is designed to model a variety of types of steel. The HSMM is broken down into thermalmechanical calculations and microstructure/mechanical properties calculations. For the microstructure/mechanical properties calculations, it currently includes material characteristics for three (3) grade families. The default grades of steel included in these families are shown below. General Grouping of the HSMM Steels for the Microstructure Calculations Family Plain carbon Grade A36 DQSK HSLA-V High Strength Low Alloy HSLA-Nb HSLA-Nb/Ti 50 HSLA-Nb/Ti 80 Interstitial Free IF-Nb rich IF-Nb lean Although the default grades include in the HSMM are certainly not an exhaustive list of hot rolled steel products, they do cover a relatively wide range of chemistries relevant to the industry. Because of the calculations within the HSMM, the user can enter the actual chemistry of the piece being modeled to obtain some additional flexibility. Additional grades of steel can be implemented via Grade Builder.
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Description no microalloying additions singly microalloying with V singly microalloying with Nb Nb/Ti microalloying with a substoichiometric Ti/N ratio Nb/Ti microalloying with an over overstoichiometric Ti/N ratio ultra low carbon

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Grade Builder
Grade Builder allows the user to configure, adapt and enhance the microstructure and thermal evolution calculations to characterize the users grades of steel. Individual companies will now be able to use the HSMM as their main process and product development tool by utilizing the Grade Builder feature for their own proprietary development activities. The first tab, Thermal and Grade Selection/Creation, allows the user to create his own grade of steel. The core grades of steel provided with the HSMM are listed as read only so that the user can view how these were created and can use these as a starting point to create his own grade. This tab allows the user to manage (New, Duplicate or Delete) his grades of steel under the Grade Management window or Thermal Grade Management window.

Launch Grade Builder

Enter the Chemistry

Create the Microstructure Grade

Create the Thermal Grade

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The second tab, Grade Calc Methods / Equations, allows the user to select the method to be used for each major algorithm utilized for the microstructure evolution, final mechanical properties and flow stress calculations. The main areas are broken down into Recrystallization, Precipitation, Transformation, Mechanical Properties and Flow Stress. Within each of these areas, the calculations required are displayed from a drop down menu for selection of one of the available options, including the ability to utilize a user-defined equation. When a specific equation is selected, a graph of the key variable is displayed along with the coefficients for that equation. If the user changes the coefficients, the graph is updated. A help button (Show Eqn) is also available that will display the equation and associated coefficients.

Select the Category

Select a Method under each Function

Characteristics of the Equation

Select an Equation for each Method

The following graphic shows a typical window displayed when the user clicks on the Show Eqn (show equation) button.

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When the user of the HSMM selects to use his own equation, the user must then develop a software subroutine to the requirements defined by a specific format. This subroutine can be developed in either C or Fortran. The following graphic shows how the pull down menu next to each function gives the user the option to enable an external (user) algorithm.

Select a User Defined Equation

The following is a small sample of the Fortran code layout for the external routine that will be used as the User Equation. Working examples with comments and instructions of how to format and implement the routine in C or Fortran are provided. The user could also use this option to enter fixed parameter values instead of equations.

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The third and final tab, Thermal Grade Parameters, allows the user to edit the coefficients/curves for the thermal properties of the steel. This includes Specific Heat, Thermal Diffusivity, Thermal Expansion, Emissivity, Yield Strength and Density.

Once the user has completed the development/enhancement of his grade of steel using Grade Builder, these grades are now available to the user and can be selected from the Calibration screen. The user selects his base grade from the drop down menu and then enters the actual chemistry of the piece being modeled. The piece being modeled should fall within an acceptable range of chemistry deviation from the base grade. The configuration for the grade of steel as developed in Grade Builder is summarized in the Calibration screen.

Summary of the Methods Used

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Results
The HSMM presents the results to the user in a variety of forms. A snapshot of the final results for the mechanical properties is available for both the single node and multiple node calculations.

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For production capability studies, the HSMM provides the user with information on cycle times, production rates and material losses (scale).

The HSMM also provides the user with the ability to graph a variety of process parameters for both the single node and multiple node calculations. For the product temperatures, the user can enter in actual mill temperatures (from pyrometers or on-line models) so that this data is plotted along with the HSMM results.

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For a breakdown of the results by area, separate screens are provided that allows the user to view the temperatures, forces and microstructure evolution at each step of the process. A pop-up window is also available that will show through thickness calculations completed by the multiple node model.

Exporting Additionally, the HSMM allows the user to export data to be stored in .CSV files, which can be easily imported into software packages such as Microsoft Excel.

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Summary Results History The Summary Results History window is used to display an historical record of the last 25 calculation runs of the model. The user has ability to select the result parameters to be displayed in the history list. The purpose of this tool is to allow the user to analyze the effects that changes in various inputs have on the results. For each run in the list, the user can enter a comment to record what changes were made before making this run. Hardcopy is available with the click of a button.

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INTEG process group, inc. Reports

This option allows the user to create and print reports of the various inputs and outputs of the model. The user is able to generate reports for the Mill Configuration, the current Rolling Schedule (both Single Node and Multiple Node), and the current Calibration / Grade summary. Once a report has been selected and generated, the user has the option to view each page of the report, print the report, and export the report to an Adobetm .pdf file.

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Validation
The models have been validated using data from several plants and good agreement has been achieved for a variety of products for temperatures, forces, grain size and final mechanical properties. The Tensile Strength is viewed as the best measure of microstructure performance since the TS test is the most repeatable in the plant and thus has the least deviation (error) built-in on the measurement side (in other words, the lab tests would generate nearly identical results if they were completed by a variety of personnel for the same piece). Grain size calculations, on the other hand, can contain the largest deviation when calculated by different people. As shown in the Excel-generated charts below, the TS comparison contains the lowest average error.

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With a minimal number of tuning coefficients in the calibration Module, the temperature model can be tuned to match measured or online model predicted temperatures through the mill and runout table areas (shown as black dots on the chart below). Once tuned, the temperature model can accurately predict temperatures under different operating conditions such as changes in speeds, reductions, or water sprays. Accurate temperature predictions are essential input for the microstructure models.

Any of the four choices for the force model (NIST, Shida, Medina, or Resistance to Deformation) can be automatically tuned in the Calibration Module to closely match the measured forces. The graph below shows how the four models compare against the measured forces after the calculated values were exported to an Excel file
Force Model Comparison
3000 Rolling Force (tonnes) 2500 2000 1500 1000 500 0
F4 F2 F1 F3 F5 RR RR RR RR RR RR RR RR RR F7 F6 2 5 7 3 1 6 8 4 9
Measured NIST Shida Medina Res-to-Def

Stand

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Database Update Utility

The HSMM now incorporates a database update utility so that projects developed by the user can continue to be used with each enhancement of the HSMM. This provides the necessary migration path to allow the user to grow with the HSMM.

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