Prediction of residual stresses by FE simulations on bimetallic work rolls during cooling

Bimetallic rolls used in the roughing stands of the Hot Strip Mill require mixed properties as a high wear resistance for the shell material and an enhanced toughness for the core material. The bimetallic roll studied in this paper is obtained from a vertical spin casting process followed by cooling and subsequent heat treatments. Failure of the compound roll sometimes occurs during the cooling stage of the casting route or later during the thermal treatments. It requires to deeply investigate the thermo mechanical metallurgical interactions generated during cooling and heat treatment in order to find the origin of cracks. For this purpose, a thermo metallurgic mechanical finite element model is used. However these numerical simulations require a high amount of mechanical, thermal and metallurgical parameters. In order to determinate these parameters, a study of available data for estimation of mechanical parameters was performed. Thermo physical parameters were obtained by DTA and DSC methods. Metallurgical characterization by inverse numerical method based on available CCT diagrams was performed to determine the TTT diagrams. First cooling numerical simulations are presented, allowing a rough estimate of residual stresses values and the identification of key parameters for predicting accurate residual stresses by sensitivity analysis.