The rolling process of rebar steel production is one of the well established manufacturing processes; however, it should be subjected to revision and redesign for productivity enhancement and power reduction throughout the slit rolling process. In this work, slitting passes are extensively reviewed and modified for the attainment of better rolling stability and reduction in power consumption. The study has been applied for grade B400B-R Egyptian rebar steel, which is equivalent to steel grade ASTM A615M, Grade 40. Traditionally, the rolled strip in the rolling pass is edged before implementing a slitting pass using grooved rolls; this produces a single barreled strip. This single barrel form causes instability in the next slitting stand on the pressing by the slitting roll knife. Multiple industrial trials are attempted to achieve the deformation of the edging stand using a grooveless roll. As a result, a double barreled slab is produced. In parallel, finite element simulations of the edging pass are performed using grooved and grooveless rolls, and similar slab geometry with single and double barreled form are produced. In addition, further finite element simulations of the slitting stand are execute using idealized single barreled strips. The power calculated by the FE simulations of the single barreled strip is (245 kW), which is in acceptable agreement with the experimental observations in the industrial process (216 kW). This result validates the FE modeling parameters such as material model and boundary conditions. The FE modeling is extended to the slit rolling stand of a double barreled strip, which was previously produced by the grooveless edging rolls. It is found that the power consumption is (165 kW) 12% lower than the power consumed (185 kW) for slitting the single barreled strip.
Keywords: finite element simulation; power reduction; rebar steel; rolling; slitting.