• 제어로봇시스템학회:학술대회논문집
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• 2004.08a
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• pp.863-868
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• 2004

Reheating furnace is an essential facility of a rod mill plant where a billet is heated to the required rolling temperature so that it can be milled to produce wire. Sometimes, it is also necessary to control a transient billet temperature pattern according to the material characteristics to prevent a wire from breaking. Though it is very important objective to obtain a correct information of a billet temperature during furnace operation. Consequently, a billet temperature profile must be estimated. In this paper, a billet heat transfer model based on FEM (Finite Element Method) with spatially distributed emission factors is proposed and a measurement is also carried out for two different furnace operation conditions. Finally, the difference between the model outputs and the measurements is minimized by using the new optimization algorithm named uDEAS(Univariate Dynamic Encoding Algorithm for Searches) with multi-step tuning strategy. Hence, the information of billet temperatures can be obtained by using proposed model on various furnace operation conditions.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.21 no.6
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• pp.961-970
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• 1997

A numerical method is presented to predict and analyze the shape of a growing billet produced from the "spray forming process" which is a fairly new near-net shape manufacturing process. It is important to understand the mechanism of billet growing because one can obtain a billet with the desired final shape without secondary operations by accurate control of the billet shape, and it can also serve as a base for heat transfer and deformation analysis. The shape of a growing billet is determined by the flow rate of the alloy melt, the mode of nozzle scanning which is due to cam profile, the initial positio of the spray nozzle, scanning angle, and the withdrawal speed of the substrate. In the present study, a theoretical model is first established to predict the shape of the billet and next the effects of the most dominent processing conditions, such as withdrawal speed of the substrate and the cam profile, on the shape of the growing billet are studied. Process conditions are obtained to produce a billet with uniform diameter and flat top surface, and an ASP30 high speed steel billet is manufactured using the same process conditions established from the simulation.imulation.

• International Journal of Control, Automation, and Systems
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• v.5 no.1
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• pp.43-50
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• 2007

Reheating furnace is an essential facility of a rod mill plant where a billet is heated to the required rolling temperature so that it can be milled to produce wire. Although it is very important to obtain information on billet temperatures, it is not feasible during furnace operation. Consequently, a billet temperature profile should be estimated. Moreover, this estimation should be done within an appropriate time interval for an on-line application. In this paper, a billet heat transfer model based on 2D FEM(Finite Element Method) with spatially distributed emission factors is proposed for an on-line billet temperature estimation and also a measurement is carried out for two extremely different furnace operation patterns. Finally, the difference between the model outputs and the measurements is minimized by using a new optimization algorithm named uDEAS(Univariate Dynamic Encoding Algorithm for Searches) with multi-step tuning strategy. The obtained emission factors are applied to a simulation for the data which are not used in the model tuning for validation.

• Proceedings of the Korea Society for Simulation Conference
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• 1999.04a
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• pp.189-193
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• 1999

본 연구는 창원특수강(주)에서 코일 등을 생산하는 압연공장의 소재인 Billet를 적치하는 Billet 야드의 물류 개선방안을 도출하는 것이 주요 연구내용이다. 이러한 연구를 위해 Billet의 작업패턴, 선진 사례, 설비투자 등을 고려하여 다양한 작업기준을 설정하고, 경영환경의 변화에 따른 다양한 경우에 대해 시뮬레이션 모형을 개발하고 대안을 비교 평가하였다. 시뮬레이션은 Simplus를 이용하녀 수행하였으며, 시뮬레이션에 필요한 작업기준 및 패턴과 관련된 자료는 작업실적 분석, 현장 전문가와의 협의 및 문헌조사를 통하여 파악하였다. 시뮬레이션의 결과는 현장 전문가들의 이해를 높이기 위하여 애니메이션을 통하여 가시화하였다.

• Journal of Electrical Engineering and Technology
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• v.11 no.6
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• pp.1729-1734
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• 2016

The surface inspection of a steel billet is a common practice in the steel manufacturing process prior to hot rolling to produce steel wire for tire cord. This billet surface inspection is an important process because flaws on the surface may cause major failures during the product manufacturing phase. This paper presents a computer simulation based on a finite element method for a magnetic flaw detector with a function of the current intensity, the number of coil turns, and the billet proceeding speed during the production phase based on the typical condition of conventional apparatus. Based on the simulation result, the magnitude of the electromagnetic field on the surface diminished with distance from the electromagnet. In addition, the increased current intensity and the increased number of coil turns actually induced a stronger electromagnetic field on the billet surface. On the other hand, the proceeding speed of a billet in its production line had no significant effects. The result in this study may assist to reduce trial and error and to minimize the opportunity costs during the optimization process by applying the findings of this study into the operation condition in the steel billet production line.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2004.05a
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• pp.31-34
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• 2004

A new extrusion process of the circular section product with helical fins could be developed by using rotating extrusion dies. The twisting of extruded product is caused by the twisted conical die surface connecting the die entrance section and the die exit section linearly. But, until now, because the process has used fixed extrusion dies, it needs high pressure in order to twist billet and form fin shape on the surface of billet. So, during extruding billet, in order not to twist billet, the extrusion dies is needed to rotate itself instead of twisting billet. And in order to rotate dies, the shape of inside contour of extrusion dies must have conical type with twisted Inclined die surface connecting the die entrance section and the die exit section linearly. The results of experiments show that, in spite of using twisted extrusion dies, twisting of the billet should not happen because of rotating dies in the opposite direction of twisting direction of billet during extruding billet, and, from the results, it shows that it can decrease the power of extrusion pressure and could prevent crack of teeth for fin forming.

• Transactions of Materials Processing
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• v.4 no.3
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• pp.214-221
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• 1995

In the paper, we have proposed a new method to determine the initial billet for the forged products using a function approximation in the neural network. The architecture of neural network is a three-layer neural network and the back propagation algorithm is employed to train the network. By utilizing the ability of function approximation of a neural network, an optimal billet is determined by applying the nonlinear mathematical relationship between the aspect ratios in the initial billet and the final products. The amount of incomplete filling in the die is measured by the rigid-plastic finite element method. The neural network is trained with the initial billet aspect ratios and those of the unfilled volumes. After learning, the system is able to predict the filling regions which are exactly the same or slightly different to the results of finite element simulation. This new method is applied to find the optimal billet size for the plane strain rib-web product in cold forging. This would reduce the number of finite element simulation for determining the optimal billet size of forging product, further it is usefully adapted to physical modeling for the forging design.

• Transactions of the Korean Society of Mechanical Engineers B
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• v.24 no.11
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• pp.1549-1554
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• 2000

A new method to determine the total heat exchange factor was proposed for the prediction of billet temperature in a reheating furnace. This method employed the squared of the difference between measured and predicted temperatures as an objective function. The real billet temperature in a walking beam type reheating furnace with 19.75m of its effective length was directly measured by thermocouples. The present method was validated by showing that the predicted billet temperature was in a good agreement with the measured one.

• Journal of the Korean Society for Precision Engineering
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• v.12 no.11
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• pp.118-124
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• 1995

In the paper, we have proposed a new technique to determine the initial billet for the forged products using a function approximation in neural network. A three-layer neural network is used and a back propagation algorithm is employed to train the network. An optimal billet which satisfied the forming limitation, minimum of incomplete filling in the die cavity, load and energy as well as more uniform distribution of effective strain, is determined by applying the ability of function approximation of the neural network. The amount of incomplete filling in the die, load and forming energy as well as effective strain are measured by the rigid-plastic finite element method. This new technique is applied to find the optimal billet size for the axisymmetric rib-web product in hot forging. This would reduce the number of finite element simulation for determining the optimal billet of forging products, further it is usefully adopted to physical modeling for the forging design

• Proceedings of the Korean Society of Propulsion Engineers Conference
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• 1996.05a
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• pp.209-216
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• 1996

The shape variation of billet was investigated by numerical method and spray forming work with variation of average substrate withdrawal velocity$\bar{V}$, withdrawal velocity change interval $\Delta$t and velocity deviation from average velocity $V_{dev}$. The shape and diameter with large$\bar{V}$, $\Delta$t, $V_{dev}$ vary seriously. When $\bar{V}$, $\Delta$t, $V_{dev}$ are smaller, the shape of billet is more simillar to that of the billet with constant withdrawal velocity. The average diameter of billet is determined by only $\bar{V}$, independent of $\Delta$t, $V_{dev}$. With $\bar{V}$, : 0.2 mm/sec $\Delta$t: 200 sec and $V_{dev}$. : 0.2mm/sec billet of constant diameter 230mm$\times$ height 1000mm were manufactured.