NEW TECHNOLOGY FOR PRODUCTION OF HIGH QUALITY LONG PRODUCTS: IMPLEMENTATION EXPERIENCE
NOVA TECNOLOGIA PARA A PRODUÇÃO DE PRODUTOS LONGOS DE ALTA QUALIDADE: EXPERIÊNCIA DE IMPLEMENTAÇÃO
Mukhopadhyay, Ananya; Galasso, Luigi Martino
http://dx.doi.org/10.4322/tmm.2011.036
Tecnol. Metal. Mater. Min., vol.8, n4, p.230-236, 2011
Abstract
A new technology has been developed for production of superior quality bars and rods. The aim is to predict and control accurately the product properties during actual processing stage itself, rather than post-production ‘product-testing’ stage (as is presently practised). The new technology capitalizes on the methodology that combines ‘advanced microstructural engineering’ and the state-of-the-art ‘data mining’ techniques such as Artificial Neural Networks (ANN) to assess microstructure and product properties. Danieli QTB PLUS System based on this technology was implemented in Riva Group; at two of their rebar mills in Europe – one in Verona (Italy), and another in Seville (Spain). The system ensures superior quality and uniformity of product, as mentioned in customer order. This has improved hit rate and reduced downgrades. This reduces the need for extensive material sampling and testing, and thereby, improves cycle time and productivity. The technology is also useful for process optimization and design of new product. This reduces product development cost, and improves resource utilization.
Keywords
Process control, Mechanical properties, Hot rolled, Bars
Resumo
A nova tecnologia foi desenvolvida para a produção de barras e fio máquina de qualidade superior. O objetivo é prever e controlar com precisão as propriedades do produto durante o processo em si, ao invés do controle de pós-produção e teste de produto (como é praticada atualmente). A nova tecnologia capitaliza a metodologia que combina tecnicas avançadas de engenharia microestrutural e o estado-da-arte em técnicas de banco de dados, como Redes Neurais Artificiais (ANN) para avaliar a microestrutura e propriedades do produto. O Sistema Danieli QTB PLUS, baseado nesta tecnologia, foi implementada pelo Grupo Riva, em duas de suas fábricas de vergalhões na Europa - uma em Verona (Itália), e outra em Sevilla (Espanha). O sistema garante qualidade superior e uniformidade do produto, conforme mencionado no pedido do cliente. Isso melhorou a taxa de acerto e reduziu processos de desclassificações de qualidade. A redução das constantes necessidades de amostragem e ensaio melhora o tempo de ciclo e a produtividade. A tecnologia também é útil para otimização de processos e desenvolvimento de novos produtos. Isso reduz o custo de desenvolvimento de produto, e melhora a utilização dos recursos.
Palavras-chave
Controle de processo, Propriedades mecânicas, Laminação a quente, Barras
Referências
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2 MUKHOPADHYAY, A. et al. New technology to meet challenges of high quality rebars – Danieli QTB plus. In: SEASI ’09 CONFERENCE, 2009, Kuala Lumpur, Malysia. [S.n.t.]
3 MUKHOPADHYAY, A. et al. QTB Plus: better control for mechanical properties of quenched and tempered bars. In: AISTECH ’09, 2009, St. Louis, USA. [S.n.t.].
4 MUKHOPADHYAY, A.; GALASSO, L. M. Danieli QTB plus: technology for quality improvement of rebars: implementation experience. In: SEASI’10 CONFERENCE, 2010, Ho Chi Minh City, Vietnam. [S.n.t].
5 KUNDU, S. et al. Modelling of microstructure and heat transfer during controlled cooling of low carbon wire rod. ISIJ International, v. 44, n. 7, p. 1217-23, 2004. http://dx.doi.org/10.2355/isijinternational.44.1217
6 JOHN, S. Complete simulation system for wire rod rolling. In: INTERNATIONAL CONFERENCE IN LONG PRODUCTS – CHALLENGES AND OPPORTUNITIES, 2004, Jamshedpur, India. Proceedings… [S.n.t.]. p. 20.1-20.8
7 SELLARS, C. M. Modelling microstructural development during hot rolling. Materials Science and Technology, v. 6, n. 11, p. 1072-81, Nov. 1990.
8 DONNAY, B. et al. Microstructure evolution of c-mn steels in the hot deformation process: the stripcam model. In: INTERNATIONAL CONFERENCE ON “MODELLING OF METAL ROLLING PROCESSES”, 2., 1996, London. Proceedings. London: Institute of Materials, 1996. p. 23-35.
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