INTERNATIONAL JOURNAL OF RESEARCH IN AERONAUTICAL AND Vol.

4 Issue 10,
MECHANICAL ENGINEERING October 2016
ISSN (ONLINE): 2321-3051 Pgs: 1-11

Defect Analysis of Angle Bar in

Hot Rolling
Bashishth Kumar Kushwaha1* and Mudit Sharma 2
1
Department of Mechanical Engineering, Roorkee Engineering &Management Technology Institute, Shamli India
2
M.E. Scholar, Department of Mechanical Engineering, NITTTR, Chandigarh, India
*
Corresponding author- [email protected]

Abstract
In this work, the study of existing process was done to find the root cause of the problem. Three dimensional
model of rolls and steel angle bar were developed in SOLIDWORKS. The models were imported in to LS-
DYNA software for simulation of the rolling process with the different combination of mill speeds and friction
coefficient. Physical and mechanical properties of raw material and temperature of ingots was specified.
Meshing of model was done for accurate representation of effective stresses, effective plastic strain and
displacement during rolling.
The analysis of the rolling process was done and results obtained in terms of equivalent stress and effective
plastic strain. At suggested process parameters viz. mill speed of 90 rpm and friction coefficient of 0.25, the
value of effective plastic strain & effective stress on the edges of steel angle bar are 0.57761 and 533.379 MPa
respectively, which are within safe limits. It has been found that mill speed and friction coefficient are the two
major factors that significantly affect the quality of rolling products. Lower value of friction coefficient requires
that number of mill passes be increased. Higher value of friction coefficient increases the sticking between
rollers and the incoming metal leading to defects in steel angle bar

Keywords: Hot Rolling, Cold Rolling, cracks, coefficient of friction, Stress

1. Introduction
The investigating the mechanism of thermal crack growth while taking into account the complex thermal and
mechanical interactions during the rolling process. They utilized the concepts of FEM for the estimation of rolls
life, from the perspective of thermal fatigue. Their work described the methodology of predicting thermal fatigue
crack growth using innovative modelling techniques and they highlights the importance to the operating
conditions [1].
The accuracy of the FE model was analyzed through a dual comparison by geometrical and by physical aspects.
The effectiveness of a new numerical subroutine was tested by a comparison with experimental values acquired
from an industrial plant tool wear, the author characterized the extent of the tool wear by wear depth. Twenty
points were used to measure tool wear depth with different area reduction, forming angle, and stretching angle
[2].There was good agreement between experimental results and the simulation in terms of wear and rolling
friction under different operating conditions. The analysis of disc-disc interaction has been presented by using
FEM technique. However this work gives rise to thoughts about possible applications in various fields [3].
The finite element model for the prediction of the steady-state thermo-mechanical behaviour of the roll-strip
system and of roll life in hot strip rolling. The model was comprised of basic finite-element models, which are
incorporated into an iterative-solution procedure to deal with the interdependence between the thermo-mechanical
behaviour of the strip and that of the work roll. However, the model addressed only a part of roll wear–related
problems, leaving the rest for future works [4].

Bashishth Kumar Kushwaha and Mudit Sharma

INTERNATIONAL JOURNAL OF RESEARCH IN AERONAUTICAL AND Vol.4 Issue 10,
MECHANICAL ENGINEERING October 2016
ISSN (ONLINE): 2321-3051 Pgs: 1-11

They used finite element analysis technique to investigate behaviour of rolls related to bending, shifting and
levelling. The effective utilization of these methods, leads improvisation of the flatness in the cold rolled sheet.
Apart from the profile of sheet, the shape was also significantly affected by the vibrations developed in mill
housing [5]. The developed procedure for the simulation of the hot rolling process. They stated that rolling is a
3D process but using the generalized plane strain method, the real 3D problem can be solved using a 2D Finite
Element Model, saving an important computing time [6].
FEM software are able to describe the kinetics of recrystallization during the process, taking into consideration
grain size refinement and grain growth. By incorporating such mathematical models, it is possible to predict the
formation process as a whole, including the final microstructure obtained for the forged part, allowing process
optimization that focuses on a higher-quality final product [7].
They developed a computer system to detect shape defects in the rolled product and determined the degree of
deformation of metal at the design stage, which allows the initial plans to approximate the final design as closely
as possible. So this system is very helpful for future researchers, would make it possible to avoid having to perform
a large number of costly and time-consuming commercial trials and to predict the defects might be formed in the
rolled product [8].The variation of the blade cross-section, the deformation stress and strain of the work-piece
keep changing during the rolling process and the conventional rolling theory is no longer valid. The complexity
and diversity of the blade cross-section determine it impossible to establish a universal theoretical model for the
rolling process [9].Finite element method is reliable and versatile analytical method that avoids bold hypothesis,
which are often involved in the classical methods such as the slab method or the energy method [10].
The sizing press followed by horizontal rolling is more efficient in width reduction than deformation by a heavy
edger mill followed by horizontal rolling. The finite-element analysis results for the deformation of a slab also
show reasonable agreement with measurements from an actual mill test, and from physical modelling experiments
[11]. The effects of process parameters such as the cooling condition of the work-rolls, the rolling speed, and the
roll metal interfacial heat-transfer coefficient on the temperature distributions in the work-rolls as well as in the
rolling metal. The comparison between the model predictions and experimental results shows the validity of the
proposed model [12]. The rapid development of computer technology and the improvement of general finite
element analysis software, especially with the development of parallel computing technique, it has become
possible to analyze cold strip rolling process and calculate the strip deformation with 3-D finite element contact
model of rolls and strip [13]. The temperature of H-beam was a downward trend in the hot rolling process,
however, local temperature display rising trend, uneven deformation of flange lead to more complex temperature
distribution, there is certain correlation between equivalent plastic stress and temperature distributions, increasing
of equivalent plastic stress as the temperature increases, research results can provide theoretical basis for rolling
regulations and reference of the production of hot rolling for H-beam [14]. The vertical roller mill 3-D model
established in Pro/E is imported into ADAMS through the data interactive software Mech/pro to analyze its stress,
and then carry out the FEA of the model loaded in ANSYS. After Comparing with the material yield limit, the
both stresses are reasonable which will meet the demand of design. This co-simulation method provides a reliable
basis for vertical roller mill design and can also be applied to other mechanical system design process [17].
A coupled thermo-mechanical finite element method computation on steel pipe rolling process, gets the residual
stress and strain change rule in the rolling process. They analyzed the influence of roller spacing and velocity
parameters on residual stress and strain, which provides a reliable theory basis for improving the performance of
hot rolling seamless steel pipe and the optimization of rolling technological parameters [18].
The roll cross angle, rolling press quantity, intersection position and rolling speed can change the size of the axial
force, axial forces may float small by the pressing ratio increases, lager by rolling speed increases, bigger by
adding more far intersection point position, This conclusions have realistic significance in cross rolling schedule
making, and provide basis theory reducing rolling axial force [19].
The ring can approximately maintain its round shape at the initial rolling period, when the process is entering the
medium period, the roundness of the ring becomes worse, and it tends to be improved at the final rolling period.
A series of ring rolling experiments were conducted. So the reliability of the finite element model of the vertical
hot ring rolling process with measurement and control was validated [20].
The formation of edge defects in hot strips, resulting from slab corner cracks generated in continuous casting.
They developed a model-based concepts for the identification of such initial slab cracks. To accomplish this task

Bashishth Kumar Kushwaha and Mudit Sharma

INTERNATIONAL JOURNAL OF RESEARCH IN AERONAUTICAL AND Vol.4 Issue 10,
MECHANICAL ENGINEERING October 2016
ISSN (ONLINE): 2321-3051 Pgs: 1-11

a systematic finite element tool Deform-3D was utilized. The numerical results clearly pointed out the significant
morphological changes of the cracks during rolling and afford valuable indications for a deeper understanding of
the underlying process details [21].
A two dimensional elastic plastic model was used to simulate the cold rolling of thick strip. They found the speed
and diameter of rolls have influence on the quality of rolling products [24].
The mechanical properties of high strength steel and mild steel at elevated temperatures. They found that yield
strength, tensile strength and elastic modulus of steels at elevated temperatures decreases [25].
2. Problem Description
The company, Shamli Steels Private Limited situated in Muzaffarnagar (U.P.), is a manufacturer of steel angle
bars which are used as structural members. Therefore strength and surface quality of hot rolled steel angle bar
are key quality parameters.
The company is facing the problem of edge cracks in steel angle bar during the hot rolling operation as shown
in Figure 1.These cracks reduce strength of the angle bar due to which such components are rejected. This results
loss in productivity and increase financial burden on company.

3. Objectives of the Present Work

The aim of present work is to carry out the investigation of edge cracks of steel angle bar during hot rolling
operation. The objectives of current work are as follows:
 Modeling of the rollers and ingot assembly for transient analysis.
 Analysis of effective stress and effective plastic strain produced in the angle bar using finite element
approach.
 To determine optimum process parameters for prevention of edge cracks in angle bar.
 To reduce scrap and quality problem.

Figure 1: Edge Crack

4. Results and Discussion

The analysis of edge cracks in steel angle bar was carried out by varying the mill speed and the friction coefficient.
The diameter of the rollers and temperature of the material were not changed as per industry requirement. Also
limit of mill speed was taken 110 rpm.
The simulation results were obtained in the terms of effective plastic strain and effective stress distribution. The
acceptance criteria of plastic strain is 0.5 in hot rolling [26]. So the plastic strain value exceeds this limit then it
will lead edge cracks in steel angle bar.
In this work the ingot and rollers assembly was subjected to mill speed of 90 rpm, 95 rpm and 100 rpm with
friction coefficient 0.20, 0.25 and 0.30. The maximum effective plastic strain was produced 1.15 at N=90 rpm
with friction coefficient 0.30 and minimum effective plastic strain was produced 0.450866 at N=90 rpm (µ=0.20)

Bashishth Kumar Kushwaha and Mudit Sharma

INTERNATIONAL JOURNAL OF RESEARCH IN AERONAUTICAL AND Vol.4 Issue 10,
MECHANICAL ENGINEERING October 2016
ISSN (ONLINE): 2321-3051 Pgs: 1-11

(a) (b)

(c)
Figure 2: Effective Plastic Strain Distribution in Angle Bar at N=90 rpm
(a) µ=0.20 (b) µ=0.25 (c) µ=0.30

(a) (b)

(c)

Bashishth Kumar Kushwaha and Mudit Sharma

INTERNATIONAL JOURNAL OF RESEARCH IN AERONAUTICAL AND Vol.4 Issue 10,
MECHANICAL ENGINEERING October 2016
ISSN (ONLINE): 2321-3051 Pgs: 1-11

Figure 3: Effective Plastic Strain Distribution in Angle Bar at N=95 rpm

(a) µ=0.20 (b) µ=0.25 (c) µ=0.30

(a) (b)

(c)
Figure 4: Effective Plastic Strain Distribution in Angle Bar at N=100 rpm
(a) µ=0.20 (b) µ=0.25 (c) µ=0.30

In this work the ingot and rollers assembly was subjected to mill speed of 90 rpm, 95 rpm and 100 rpm with
friction coefficient 0.20, 0.25 and 0.30 the maximum effective stress was produced 582 MPa at N=100 rpm with
friction coefficient 0.30 and minimum effective plastic strain was produced 417.7 MPa at N=95 rpm (µ=0.20)

(a) (b)

Bashishth Kumar Kushwaha and Mudit Sharma

INTERNATIONAL JOURNAL OF RESEARCH IN AERONAUTICAL AND Vol.4 Issue 10,
MECHANICAL ENGINEERING October 2016
ISSN (ONLINE): 2321-3051 Pgs: 1-11

(c)

Figure 5: Effective Stress Distribution in Angle Bar at N=90 rpm

(a) µ=0.20, (b) µ=0.25, (c) µ=0.30

(a) (b)

(c)

Figure 6: Effective Stress Distribution in Angle Bar at N=95 rpm

(a) µ=0.20, (b) µ=0.25, (c) µ=0.30

Bashishth Kumar Kushwaha and Mudit Sharma

INTERNATIONAL JOURNAL OF RESEARCH IN AERONAUTICAL AND Vol.4 Issue 10,
MECHANICAL ENGINEERING October 2016
ISSN (ONLINE): 2321-3051 Pgs: 1-11

(a) (b)

(c)
Figure 7: Effective Stress Distribution in Angle Bar at N=100 rpm
(a) µ=0.20, (b) µ=0.25, (c) µ=0.30

The figures 2-4 shows plastic strain development in the angle bar. Maximum plastic strain (1.15697) region is
represented by red colour zone at the status bar. And the figures 5-7 shows effective stress development in the
angle bar. Maximum effective stress (542.229 MPa) is represented by red colour zone at the status bar. The various
colours at the status bars represents variation of plastic strain and stress values.
The effective plastic strain and effective stress results obtained for angle bar during rolling at mill speed 90, 95
and 100 rpm and different friction coefficient are plotted in the form of graphs as shown in Figures 8-9.

Bashishth Kumar Kushwaha and Mudit Sharma

INTERNATIONAL JOURNAL OF RESEARCH IN AERONAUTICAL AND Vol.4 Issue 10,
MECHANICAL ENGINEERING October 2016
ISSN (ONLINE): 2321-3051 Pgs: 1-11

Figure 8: Effective Plastic Strain Variation with Friction Coefficient (0.20 To 0.30) (a) N=90 rpm, (b) 95 rpm,
(c) 100 rpm

Figure 9: Effective Stress Variation with Friction Coefficient (0.20 To 0.30) At (a) N=90 rpm, (b) N=95 rpm,
(c) N=100 rpm

The figure 8 shows variation of plastic strain with increased friction coefficient value at mill speed 90 rpm, 95
and 100 rpm. The plastic strain increases with increasing friction coefficient. And the figure 9 shows variation of
effective stress with increased friction coefficient at mill speed 90, 95 and 100 rpm. The effective stress increases
with increasing friction coefficient.

Bashishth Kumar Kushwaha and Mudit Sharma

INTERNATIONAL JOURNAL OF RESEARCH IN AERONAUTICAL AND Vol.4 Issue 10,
MECHANICAL ENGINEERING October 2016
ISSN (ONLINE): 2321-3051 Pgs: 1-11

5. Recommendations
The process parameters used by company for production of steel angle bar at 9th mill pass were mill speed of 100
rpm and friction coefficient of 0.30.
The optimum process parameters obtained by modelling and simulation of the process followed by data analysis
was shown in Table 1.

Table 1: Optimum Process Parameters

S.No. Mill Speed Friction Coefficient Effective plastic Effective stress

(rpm) Strain (Von-mises), MPa
1 90 0.25 0.57761 533.379

So it is suggested that mill speed of 90 rpm and friction coefficient of 0.25 be used for the rolling of steel angle
bars as the effective plastic strain and effective stress are observed to be within permissible limit under these
conditions. It is also observed that effective plastic strain and effective stress remain in permissible limit for mill
speed of 90 rpm and friction coefficient of 0.20 as well. But the lower value of friction coefficient requires that
number of mill passes be increased. Higher value of friction coefficient increases the sticking between rollers and
the incoming metal. This leads to defect in angle bar. Therefore it is also suggested that the rollers be cooled at
9th mill pass where a large reduction in height of incoming metal occurs.

6. Conclusions
The following conclusions are drawn on the basis of analysis of rollers and ingot assembly.
 The three dimensional model of rolls and steel angle bar were developed to simulate the hot rolling of
C20 carbon steel using finite element analysis software LS- DYNA 2015. The analysis of the rolling
process was done and results obtained in terms of equivalent stress and effective plastic strain.
 The effects of the friction on the rolling of steel angle bar were studied for friction coefficient values of
0.20 to 0.30. The simulation results indicate that the value of friction coefficient affects the effective
stress and effective plastic strain during rolling of incoming metal.
 It is observed that the plastic strain distribution in steel angle bar after 9th mill pass, is not homogeneous
on edges and it is more than design value of 0.5 for C20 carbon steels at original process parameters.
 Simulation results indicate that high plastic strain contours are generated in steel angle bar with increased
value of friction coefficient at constant mill speed.
 The effects of mill speed on the deformation during rolling were examined. It is observed that mill speed
has an effect on the effective stress and effective plastic strain distribution during rolling.
 The effective plastic strain and effective stress on the edge of steel angle bar were obtained. At suggested
process parameters viz. mill speed of 90 rpm and friction coefficient of 0.25, the value of effective plastic
strain & effective stress on the edges of steel angle bar are 0.57761 and 533.379 MPa respectively, which
are within safe limits.

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INTERNATIONAL JOURNAL OF RESEARCH IN AERONAUTICAL AND Vol.4 Issue 10,
MECHANICAL ENGINEERING October 2016
ISSN (ONLINE): 2321-3051 Pgs: 1-11

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MECHANICAL ENGINEERING October 2016
ISSN (ONLINE): 2321-3051 Pgs: 1-11

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