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Corresponding authors.
E-mail addresses: mylife@posco.com (I.H. Son), joodong@posco.com (J.D. Lee), ytim@kaist.ac.kr (Y.T. Im).
disappearance of these surface defects in wire rod rolling are
not yet fully gured out and preventive measures are not well
developed although many studies to investigate the mecha-
nism have been carried out.
The engineers of the Eisenh uttenleute (1973) collaborated
in dening wire rod defects, describing these phenomena
according to their occurrence and the possibility of confusing
themwith other defects. The typical illustrations and descrip-
tions of the defects were useful aid in the early detection
and elimination of the possible causes of the defect and stan-
dardizing defect nomenclature. Total 21 kinds of the surface
defects such as cracks, laps, scratches, surface decarburiza-
tion, etc. were categorized in terms of occurrence, detection,
and possibility of confusion with other defects. Sychkov et al.
0924-0136/$ see front matter 2007 Elsevier B.V. All rights reserved.
doi:10.1016/j.jmatprotec.2007.11.129
92 j ournal of materi als processi ng technology 2 0 1 ( 2 0 0 8 ) 9196
Fig. 1 Schematic diagram for determining the contact
nodes on the free surfaces.
(2006) classied various types of the surface defects of the wire
rods transformed from defects in steelmaking process. They
pointed out that accurate classication of surface defects on
rolled products in terms of their causes and where they were
formed in the rolling process was not easy. For example, it is
sometimes confusing to distinguish laps fromrolled-in cracks
or to distinguish rolled-in scabs from folds.
Barlow et al. (1984) examined the edge surface cracking
of bars and wire rods by rolling plasticines in hand-operated
mills. They concluded that the presence of tensile forces
had a pronounced effect on surface cracking and the cracks
were originated in the low-spread regions to relieve the ten-
sile stress since longitudinal elongation of these edge regions
exceeded the ductility of the material. Moreover, they men-
tioned that roll-pass design including alignment, roll gap
control should be adjusted and scale must be removed from
the billet surface at an early stage of rolling, otherwise it can
cause a pitted surface nish. Kim et al. (1999) investigated the
relationship between the wrinkle defects of wire rods and roll
caliber design. They cut off the samples of the billet in each
stands of wire rod mill and then analyzed the samples. They
pointed out that the both-side rolling sequence design of the
roughing stage made center part of a billet have less spread
width than that of other parts. Im et al. (2004) found that the
wrinkle defect could be originated from the ow localization
phenomenonexplained by DMM(dynamic material modeling)
technique (Venugopal et al., 1995). They suggested the appro-
priate roll shapes and temperature ranges which reduced the
wrinkle defect withanaidof the hot upsetting test andnumer-
ical simulations.
Ervasti and St ahlberg (1999) investigated the evolution of
surface cracks in longitudinal and transversal directions in
plate rolling using FE simulations. Eriksson (2004) carried out
the numerical simulations to see the closing and opening of
the V-shaped cracks in oval-round series. He conrmed from
the experiments that the false round-oval series were bene-
cial compared to the square-oval series in that a surface crack
in the groove bottom opened up during rolling at the same
time its depth was reduced. Shinohara and Yoshida (2005a,b)
carried out the numerical simulations to examine the defor-
Fig. 2 Denition of the surface notch shape and locations
(1: top; 2: middle; 3: bottom).
mation behavior of surface cracks in rolling comprising box
and oval passes to treat the roughing mill stands. Most of the
initial cracks developed into the overlaps after rolling. The
crack depth at free surface, where the cracks do not come
into contact with roll surface, increased, whereas the crack
depth decreased when cracks come into contact with roll
and are subjected to compressive stress. They also modeled
the crack removal by grinding wire rods and found out that
ground surface was recovered during multi-pass wire draw-
ings. Takezawz (2005) investigatedthe relationshipof the crack
depth of rectangular shape according to the initial location
with experiments and analyses and also inuence of caliber
corner radius on depth of defect. Kushida (2005) compared the
strain distribution and maximum depth of observed defects
using FE simulation.
In current study, the deformation behavior of intentionally
generated surface defects with notch shapes was focused in
order toinvestigate the effect of notchsize andinitial locations
using the numerical simulations. For this purpose, FE program
to handle contact treatment was developed to simulate the
multi-pass rolling.
2. Finite element modeling
2.1. Contact algorithm
In rolling simulation with notches, free surfaces between the
notches can meet each other and penetrate without proper
boundary constraint. Inthe current study, the free surface con-
Table 1 Roll setups and the temperature conditions (O:
oval; R: round; H: horizontal; V: vertical)
Pass no. Type Temperature (
C) RA (%)
1 O, H 930 29
2 R, V 920 17
3 O, H 912 19
4 R, V 905 15
j ournal of materi als processi ng technology 2 0 1 ( 2 0 0 8 ) 9196 93
Fig. 3 Deforming notch shapes in the rst pass rolling simulation.
tact phenomenon was treated as a contact problem between
deformable bodies and the contact searching and constraint
algorithms developed by Hahn and Im (1995) were currently
revised for three-dimensional rolling simulation.
For contact treatment between free surfaces, contacting
nodes must rst be identied during simulations. For a free
surface node, the normal distance between this node and all
opposite surface segments as showninFig. 1 was calculated. If
this distance (l) was within specied tolerance, l
tol
=0.001, this
node was determined to be a free surface contact node. This
process was repeated until all free surface nodes had been
processed with contact searching scheme.
Once all contacting nodes on free surfaces have been iden-
tied, proper boundary conditions should be applied in order
to prevent penetration between contacting free surfaces. The
penalty method was introduced to enforce this impenetra-
bility condition. In this method, a constraint contact force
depending on the amount of relative velocity was calculated
as follows:
=
S
C
F
n
v
i
dS
C
=
S
C
v
rel
v
i
dS
C
(1)
where v
i
, v
rel
, and are the nodal velocity, relative velocity
between free surface contact nodes and contact area, S
c
, and
penalty constant in that order. This weak form was added to
the traction boundary term.
2.2. FE model
Linear hexahedral elements for FE simulations were gener-
ated with the sweeping method from the two-dimensional
quadrilateral elements, in all the simulations 3260 brick
elements were used. The round billet of 28mm in diam-
eter was rolled through four passes with roll calibers in
reference (Lee et al., 2000) to produce a round shape of
approximately 19mm in diameter. Three notches were made
at the top, middle, and bottom locations although notches
are observed at various locations of the billet in rolled wire
rods. The locations of the surface notches on a quarter
simulation model are shown in Fig. 2. A notch shape was
dened with two parameters, notch depth (d) and inclina-
tion angle (). The size of a notch was 1mm in depth and
two angle conditions, 30
(Case I) and 60