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Module 4 - Part 1 - Rolling Exercise

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30 views

Module 4 - Part 1 - Rolling Exercise

Uploaded by

Amna Omer
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Flat Rolling and Its Analysis

• Flat rolling involves the rolling of workpieces of rectangular cross section in


which the width is greater than the thickness; e.g. slabs, strips, sheets and
plates.

• Draft is amount of thickness reduction and described as:

d = t0 − t f
where d = draft, mm; t0 = starting thickness, mm; and tf = final thickness, mm.

• Draft is sometimes expressed as a fraction of the starting stock thickness,


called the Reduction (r):
d
r=
t0
Flat Rolling and Its Analysis

Side view of flat rolling, indicating before and after thicknesses,


work velocities, angle of contact with rolls, and other features.
Flat Rolling and Its Analysis
• Spreading: the increase in width due to rolling, described as:

• Constant volume
towoLo = t f wf Lf
where wo and wf are the before and after work widths, mm; and Lo and Lf are the before and
after work lengths, mm.

• Similarly, before and after volume rates of material flow must be the same,
so the before and after velocities can be related:
• Constant volume rate

towovo = t f wf vf
where vo and vf are the entering and exiting velocities of the work.
Flat Rolling and Its Analysis
Spreading in Flat Rolling

tf

to

Increase in strip width (spreading) in flat rolling. Note that similar


spreading can be observed when dough is rolled with a rolling pin.
Flat Rolling and Its Analysis
• The amount of slip between the rolls and the work can be measured by
means of the forward slip, a term used in rolling that is defined

• where s is forward slip; vf is final (exiting) work velocity, m/s (ft/sec); and vr
is roll speed, m/s (ft/sec).

• True strain is expressed by:


to
 = ln
tf
• The true strain can be used to determine the average flow stress Yf (MPa)
applied to the work material in flat rolling:

K n
Yf =
1+ n
The average flow stress is used to compute estimates of force and power in rolling.
Flat Rolling and Its Analysis
• There is a limit to the maximum possible draft that can be accomplished in
flat rolling with a given coefficient of friction, defined by:

dmax = 2R
where dmax = maximum draft, mm; μ = coefficient of friction; and R = roll radius, mm.

• Rolling force (F, N) can be expressed as:


F = Y f wL
• Contact length (L, mm) is described as:

L = R(to − t f )
Flat Rolling and Its Analysis
• The torque (T) required to drive each roll are:
T = 0.5FL

• The total power (for two rolls), in S.I. units, is

where F is in newtons, L is in meters, and N is the revolutions per minute of the


roll.

• The total power (for two rolls), in English units, is

where F is in pounds and L is in feet.


Example 1
A 42.0-mm-thick plate made of low carbon steel is to be reduced to
34.0 mm in one pass in a rolling operation. As the thickness is
reduced, the plate widens by 4%. The yield strength of the steel plate
is 174 MPa and the tensile strength is 290 MPa. The entrance speed
of the plate is 15.0 m/min. The roll radius is 325 mm and the
rotational speed is 4.90 rev/min. Determine
(a) the minimum required coefficient of friction that would make this
rolling operation possible,
(b) exit velocity of the plate,
(c) forward slip.
b) Plate widens by 4%.
Solution: towovo = tfwfvf ………………(1)
(a) Maximum draft dmax = μ2 R wf = 1.04 wo ……………….(2)
42(wo)(15) = 34(1.04wo)vf
Given that d = to - tf = 42 - 34 = 8.0 mm,
vf = 42(wo)(15)/ 34(1.04wo) = 630/35.4
μ2 = 8/325 = 0.0246
= 17.8 m/min
μ = (0.0246)0.5
= 0.157 (c) vr = 2π rN= 2π(0.325) (4.90) = 10.0 m/min
s = (vf - vr)/vr = (17.8 – 10)/10 = 0. 78
Example 2
An annealed copper strip 250 mm wide and 25 mm thick is rolled to
a thickness of 20 mm in one pass. The roll radius is 300 mm, and the
rolls rotate at 100 rpm. Calculate the roll force and the power
required in this operation. Given that the average true stress is 180
MPa
Rolling Mills
• Rolling mill configurations:

– Two-high: consists of two opposing rolls, and the configuration


can be either reversing or nonreversing.

(a) two-high rolling mill.


Rolling Mills
• Rolling mill configurations:

– Tandem rolling mill : consists of a series of rolling stands,


aimed at higher throughput rates.

(e) tandem rolling mill.


Example 3
Consider a rolling operation of an annealed copper strip 250 mm
wide and 30 mm thick. The roll radius is 300 mm, and the rolls rotate
at 100 rpm. The friction coefficient is 0.15. The average flow true
stress is 180 MPa. The target is to have a final thickness of 10 mm.
(a) Show that a one pass rolling operation can not be performed
(b) Check if two-pass operation can be conducted by dividing the
range as follows:
(1) First pass: to = 30 mm, tf = 20 mm
(2) Second pass: to = 20 mm, tf = 10 mm
(c) Calculate the required power to perform for each step of the
rolling pass performed in (b).

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