ME206 – Manufacturing Process I

Lecture 12 – Analysis of Rolling process

Amber Shrivastava
Department of Mechanical Engineering,
Indian Institute of Technology Bombay

Acknowledgement: Prof. Pradeep Dixit

1
 Rolling
• Deformation process in which work thickness is reduced by compressive
forces exerted by two opposing rolls
• Rotating rolls perform two main functions:
– Pull the work into the gap between them by friction between
workpart and rolls
– Simultaneously squeeze the work to reduce its cross section
• Can be hot or cold rolling : based on operating temp
– Flat rolling - used to reduce thickness of a rectangular cross section
– Shape rolling - square cross section is formed into a shape such as
an I-beam

2
 Rolling types : Cold / Hot rolling
• Thick sheets (> 6mm) are generally hot rolled at 0.5-0.8 Tm
• Recrystallized microstructure – new grains are formed
• Cold rolling is done at 0.3Tm (well below recrystallization temp)
• Good surface finish and dimensional control
• Final rolling process is mostly cold rolling
• In cold rolling, strain hardened microstructure – plastically
deformed grains elongated in rolling direction

3
Types of rolling

no change in ext diam

4
Rolled products made of steel

5
 Shape Rolling
• Work is deformed into a contoured cross section rather than flat
(rectangular)
• Achieved by passing work through rolls that have the reverse of
desired shape
• Products include:
– Construction shapes such as I-beams, L-beams, and U-channels
– Rails for railroad tracks/ Round and square bars and rods

6
 Thread Rolling and Ring Rolling
• Used to form threads on cylindrical parts by rolling between two dies

• Ring Rolling : Deformation process in which a thick-walled ring of

smaller diameter is rolled into a thin-walled ring of larger diameter
– Hot working for large rings, Cold working for smaller rings
• As thick-walled ring is compressed, deformed metal elongates, causing
diameter of ring to be enlarged

adjustable 7
 Rolling Mills
• Multiple rolls can be used to achieve higher degree of thickness
reduction in a Rolling mill:
– Two-high, Three-high, Four-high(with backing rolls), Tandem
rolling mill – sequence of two-high mills
• Multiple backing rolls allow even smaller roll diameters

8
 Rolling terminology

(projected)

• Draft: reduction in thickness

• Contact length : length of contact between roll and workpiece
• Angle of contact : 
• Roll speed Vr

9
 Entry condition and maximum reduction
• Radial force applied by the rolls (𝑃)
pushes it away from the rolls Entry of billet
• Frictional force (µ𝑃) tries to pull it into into the roll
gap 𝑅
the roll gap
• Billet will enter the roll gap if there is net 𝜃
positive force in the direction of rolling, 𝑃 𝜇𝑃
i.e., 𝜇𝑃
𝑃
– 𝜇𝑃𝑐𝑜𝑠𝜃 ≥ 𝑃𝑠𝑖𝑛𝜃
– 𝜃𝑚𝑎𝑥 = 𝑡𝑎𝑛−1 𝜇 OR 𝜇 ≥ tan 𝜃
• Maximum possible reduction in billet
height (Δ𝑕𝑚𝑎𝑥 ) will be:
– Δ𝑕𝑚𝑎𝑥 = 2𝑅 1 − 𝑐𝑜𝑠𝜃𝑚𝑎𝑥 = 𝜃 2 𝑅 ≈ 𝜇2 𝑅
• In order to increase Δ𝑕𝑚𝑎𝑥 in a single
pass:
– Increase coefficient of friction (𝜇) 𝜃
𝑃
– Increase radius/diameter of rolls (𝑅)
𝜇𝑃 10
 Friction coefficient in rolling
• In cold-rolling, the value of friction coefficient is quite low (0.05 – 0.1),
therefore large thickness reduction is difficult to achieve
• In hot rolling, friction coefficient is high (>0.3) and is given by:
• 𝜇 = 𝑘1 𝑘2 𝑘3 1.05 − 0.0005 𝑇
• 𝑇: billet temperature in C
• 𝑘1: coefficient for effect of material of rolls,
– 0.8 for Cast iron/ 1.0 for steel rolls
• 𝑘2: coefficient for influence of rolling speed, (from following graph)
• 𝑘3: coefficient for material to be rolled, 1.0 for mild steel/ 1 – 1.3 for
alloy steel
Graph showing 𝑘2 with rolling
speed
𝑘2: 1.0 for rolling speed 2
m/s, 0.62 for speed 6 m/s,
0.40 for 20 m/s

11
 Contact area between rolls and workpiece
• Area of contact between rolls and deforming
material decide the load on the rolls
• Curved area of contact : 𝑅𝜃𝑤𝑚
– 𝑅: roll radius,𝜃: angle of contact in radians,
1
– 𝑤𝑚: average width of contact area = 𝑤1 + 𝑤2
2
• Vertical component of the radial pressure (𝑃) on
rolls is considered
• Projected area of contact: 𝐿𝑤𝑚
– 𝐿 is the length of contact projected on the
middle plane for rolling
– 𝐿 = 𝑅𝜃 𝑅 − Δ𝑕/2 Δ𝑕
cos 𝜃 = =1−
𝑅 2𝑅
– 𝐿 ≅ 𝑅Δ𝑕
– Δ𝑕 is also known as ‘draft’
• Maximum draft possible: 𝑕1 − 𝑕2 = 𝜇2 𝑅

12
 Rolling : Preliminary calculations
• If the roller width (w) and average projected contact length (L) is
known, than the average rolling force (F) can be calculated:
• Roll force: 𝐹 = 𝐿𝑤𝜎𝑓
• Projected contact length 𝐿 = 𝑅(𝑕1 − 𝑕2 )
• True stress 𝜎 = 𝐾𝜀 𝑛
𝜀𝑓𝑛
• Average flow stress 𝜎𝑓 = 𝐾 ;
𝑛+1
• K: strength constant, n:strain hardening index
𝑖𝑛𝑡𝑖𝑎𝑙 𝑡𝑕𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑕1
• Final strain 𝜀𝑓 = ln( )
𝑓𝑖𝑛𝑎𝑙 𝑡𝑕𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑕2
𝐿
• Torque: 𝑇 = 𝐹( )
2
𝜋𝐹𝐿𝑁
• Power per roll (in KW):
60,000

13
Leading and lagging zones in rolling process

𝑅
𝑉𝑟

𝜃
𝐸𝑛𝑡𝑟𝑦 𝑠𝑒𝑐𝑡𝑖𝑜𝑛 𝑃
𝛾 𝐸𝑥𝑖𝑡 𝑠𝑒𝑐𝑡𝑖𝑜𝑛
Δ𝑕/2

𝑉1 𝜇𝑃 𝑉2

𝐿𝑎𝑔𝑔𝑖𝑛𝑔 𝑧𝑜𝑛𝑒 𝐿𝑒𝑎𝑑𝑖𝑛𝑔 𝑧𝑜𝑛𝑒

𝑁𝑒𝑢𝑡𝑟𝑎𝑙 𝑠𝑒𝑐𝑡𝑖𝑜𝑛
𝐿

14
 Rolling force

Neutral section

a = 0.4-0.5L (in cold rolling),

= 0.45-0.5 L (in hot rolling)

• Pressure applied by the rolls on the workpiece is not constant

• It increases from entry point, reaches max at neutral point and then
starts reducing
• Magnitude of force inserted by workpiece of rolls is variable
– Higher at entry point and then gradually reduces
• Assuming that force is acting in the middle of contact arc
– Torque : F (L/2) 15
 Rolling analysis

• Exit strip velocity > entry velocity

• Roll-strip projected contact length = 𝑅(𝑕0 − 𝑕𝑓 )
• At neutral point, roll and workpiece has same speed
• At all points (except neutral point), difference in speed of roll and
workpiece causes frictional forces that act in direction of neutral point
𝑉𝑟 −𝑉0 𝑉𝑓 −𝑉𝑟
• Backward slip = Forward slip =
𝑉𝑟 𝑉𝑟
• For entry of workpiece into rolls 𝜇 ≥ tan 𝛼

16
Mechanics of Rolling : Leading and lagging zones
• In the rolling process, there are two regions depending upon the speed
of billet with respect to the surface speed of the rolls
• Entry section: Speed of billet (𝑉0) < surface speed of rolls (Vr)
• At exit, Speed of billet (𝑉𝑓 )> surface speed of rolls (Vr)
• Neutral section: billet speed = roll speed (Vr)

𝑉𝑓 −𝑉𝑟
• % 𝑓𝑜𝑟𝑤𝑎𝑟𝑑 𝑠𝑙𝑖𝑝 𝑜𝑛 𝑒𝑥𝑖𝑡 𝑠𝑖𝑑𝑒 = . 100
𝑉𝑟
𝑉 −𝑉
• % 𝐵𝑎𝑐𝑘𝑤𝑎𝑟𝑑 𝑠𝑙𝑖𝑝 𝑜𝑛 𝑒𝑛𝑡𝑟𝑦 𝑠𝑖𝑧𝑒 = 𝑟 𝑖 . 100
𝑉𝑟

17
 Example
• A 5 mm thick sheet needs to reduce to final thickness of 3 mm by
using rolling (roll diameter : 75 mm). Roll surface velocity and exit
velocity of sheet is 90 m/min and 120 m/min. Find out the neutral
point position (use simple geometry)?

• Solution:
– Volume conservation law : find sheet velocity at entrance
– Sheet velocity at entry, neutral point (same as roll surface
velocity), and at exit point is known
– Contact angle is also known

18
 Example
• A 200 mm wide strip having thickness of 25 mm goes under rolling.
Roll diameter is 500 mm. Total reduction required in a single pass is
3 mm. Roll rotation speed 50 rpm. Strength coefficient and strain
hardening coefficient of the material is 275 MPa, and 0.15,
respectively. Friction coefficient between rolls and workpiece is 0.12.
Find out the roll force, torque and required motor power?

• Solution:
– For large rolls (𝑅 ≫ 𝑡), projected contact length L = 𝑅(𝑕0 − 𝑕𝑓 )
• (27.4 mm)
𝑕𝑖
– Find true strain 𝜀 = ln (0.128)
𝑕𝑓
𝐾𝜀𝑛
– Average true stress during rolling : 𝜎𝑎𝑣𝑔 = (175.7 MPa)
𝑛+1
– Roll force F: Average stress * area = 𝜎𝑎𝑣𝑔 𝐿𝑤 (1445 kN)
𝐿
– Torque 𝑇 = 𝐹
2
– Power 𝑃 = 𝑇𝜔 19
 Mechanics of Rolling : Assumptions

• The rolls are straight and rigid cylinders (no elastic deformation)
• Width of the strip is much larger than its thickness.
• No significant widening of strip is taking place, i.e., the problem is of
1
plain strain type (𝜀2 = 0; 𝜎2 = 𝜎1 + 𝜎3 )
2
• Coefficient of friction µ is relatively low and constant over the entire
roll-workpiece interface
• Yield stress of material remains constant for the entire operation and
its value is average value at the start and end of the rolling 20
 Mechanics of Rolling process
• Roll pressure (𝑝𝑥 ) acting in the radial direction at any given position 𝑥
• Direction of the frictional force (𝜇𝑝) depends upon the relative velocity of
the workpiece, where p is the pressure exerted by the rolls on the
workpiece
• Frictional stresses (𝜏𝑥 ) acting tangentially to the contacting roll surfaces in
the direction of roll surface velocity
• Stresses acting in the direction of width of the strip. The slab has height
2𝑦𝑥 on the smaller side and 2(𝑦𝑥 + 𝑑𝑦) on the bigger side

Lagging zone 𝑝𝑥
𝜃 Leading zone 𝑝𝑥
(Entry) (Exit)
𝑥 = 𝜇𝑝𝑥 𝑥
𝑦 + 𝑑𝑦
x 𝑦 𝜎𝑥 + 𝜎𝑥 x

𝜎𝑥 + 𝑑𝜎𝑥
𝑥 𝑥

𝑝𝑥 𝑝𝑥
Direction of frictional force is towards neutral point and changes at the neutral point
21
 Mechanics of Rolling process
• 2 𝜎𝑥 + 𝑑𝜎𝑥 𝑦 + 𝑑𝑦 − 2𝜎𝑥 𝑦 + 2𝑅𝑑𝜃. 𝑝 sin 𝜃 ∓ 2𝑅𝑑𝜃 𝜇𝑝 cos 𝜃 = 0 Force balance
• ± symbol indicates that the direction of frictional forces will change
– From entry to neutral point, friction force be along with the roll
surface velocity, towards neutral point
– After neutral point, frictional force be opposite to the roll surface
velocity
• As 𝜃 is very small (normally < 5), sin 𝜃~𝜃; 𝑐𝑜𝑠𝜃~1
• ∴ 2 𝜎𝑥 + 𝑑𝜎𝑥 𝑦 + 𝑑𝑦 − 2𝜎𝑥 𝑦 + 2𝑅𝑑𝜃. 𝑝𝜃 ± 2𝑅𝑑𝜃𝜇𝑝 = 0
• Neglecting the higher order terms,
– 2𝑦𝑑𝜎𝑥 + 2𝜎𝑥 𝑑𝑦 + 2𝑅𝑑𝜃. 𝑝𝜃 − 2𝑅𝑑𝜃𝜇𝑝 = 0
– 𝑑 𝑦𝜎𝑥 − 𝑅𝑝 𝜇 − 𝜃 𝑑𝜃 = 0
𝑑 𝑑
– 𝜎𝑥 𝑦 − 𝜇 − 𝜃 𝑅𝑝 = 0 OR 𝜎𝑥 𝑦 = ±𝜇 − 𝜃 𝑅𝑝
𝑑𝜃 𝑑𝜃
• As the frictional forces are relatively small in cold rolling process (~ 0.1),
the principal stresses can be taken as the following:
– 𝜎𝑥 = 𝜎1 ; −𝑝 = 𝜎3
This assumption allows us to use the Von Mises criteria

22
 Mechanics of Rolling process
1
• In case of plain strain case: 𝜀2 = 𝜎2 − 𝜈(𝜎1 + 𝜎3 ) = 0;
𝐸
1
– 𝜎2 = 𝜎1 + 𝜎3 ; here 𝜐 = 0.5 in plastic deformation*
2
1
– Therefore, 𝜎2 = 𝜎𝑥 − 𝑝
2
• *Rigid perfectly plastic material behavior is a simplifying
assumption commonly used in modeling of plastic deformation of
materials.
• For an incompressible material, perfectly plastic response requires
a Poisson's ratio of 0.5 to enforce incompressibility.

23
 Mechanics of Rolling process
• Using the von-Mises yield condition:
𝜎𝑌
– (𝜎1 − 𝜎2 )2 +(𝜎2 − 𝜎3 )2 +(𝜎3 − 𝜎1 )2 = 6𝐾2(= 2𝜎𝑌 2) 𝐾=
1 3
– 𝜎1 = 𝜎𝑥 ; 𝜎2 = 𝜎𝑥 − 𝑝 ; 𝜎3 = −𝑝
2 K= Shear yield stress
1 2 1 2
• ∴ 𝜎𝑥 − 𝜎𝑥 − 𝑝 + 𝜎𝑥 − 𝑝 + 𝑝 + −𝑝 − 𝜎𝑥 2 = 6𝐾 2
2 2
1 1
• (𝑝 + 𝜎𝑥 )2 + (𝑝 + 𝜎𝑥 )2 +(𝑝 + 𝜎𝑥 )2 = 6𝐾 2
4 4
• 𝑝 + 𝜎𝑥 = 2𝐾; 𝜎𝑥 = 2𝐾 − 𝑝
𝑑
• Now, from the basic equation 𝜎𝑥 𝑦 − 𝜇 − 𝜃 𝑅𝑝 = 0
𝑑𝜃
𝑑
– [𝑦 2𝐾 − 𝑝 ] − 𝜇 − 𝜃 𝑅𝑝 = 0
𝑑𝜃
• Considering the change in the direction of frictional force both before
and after the neutral points
𝑑
• [𝑦 2𝐾 − 𝑝 ] − ±𝜇 − 𝜃 𝑅𝑝 = 0
𝑑𝜃
– Positive sign for region before the neutral point, and negative
after the neutral section
24
 Roll pressure – before and after neutral point
𝑑
• [𝑦 2𝐾 − 𝑝 ] − ±𝜇 − 𝜃 𝑅𝑝 = 0
𝑑𝜃
𝑑 𝑝
• 2𝐾𝑦 1− + 𝜃 ± 𝜇 𝑅𝑝 = 0
𝑑𝜃 2𝐾
• As 𝜃 is small, y can be expressed in the form of
𝑡𝑓 𝜃2
𝑦𝑓 = + 𝑅
2 2
𝑑 𝑝 𝑝
• − 𝑡𝑓 + 𝑅𝜃 2 +2 𝜃∓𝜇 𝑅 =0
𝑑𝜃 2𝐾 2𝐾
𝑝
𝑑 2𝐾 2𝑅 𝜃∓𝜇 𝑑𝜃
• 𝑝 =
𝑡𝑓 +𝑅𝜃2
2𝐾
• Integrating the above equation:
𝑝 1 𝑅 𝐶
• ln = ln 𝑡𝑓 + 𝑅𝜃 2 ∓ 2𝜇 𝑅 tan−1 𝜃 + ln
2𝐾 𝑡𝑓 𝑡𝑓 2𝑅

𝑝 𝑦 𝑅 𝑅
• = 𝐶 𝑒 ∓𝜇𝜆 ; where 𝜆 = 2 tan−1 𝜃
2𝐾 𝑅 𝑡𝑓 𝑡𝑓

25
 Roll pressure – before and after neutral point
𝑝 𝜎
• From the von-Mises condition, we know that 𝑝 + 𝜎𝑥 = 2𝐾; 𝑜𝑟 = 1 − 2𝐾𝑥
2𝐾
• In the beginning of the rolling process (upto the neutral point – Entry zone),
𝑝𝑖 𝜎 𝑡
• 2𝐾
𝑥𝑖
= 1 − 2𝐾 = 𝐶 − 2𝑅𝑖 𝑒 −𝜇𝜆𝑖 ;
𝑅 𝑅 2𝑅 𝜎𝑥
• 𝜆𝑖 = 2 tan −1
𝜃 and 𝐶 − = 1 − 2𝐾𝑖 𝑒 +𝜇𝜆𝑖
𝑡𝑓 𝑡𝑓 i 𝑡𝑖

• 𝐶 − is the value of constant C before the neutral point

• For region beyond the neutral point (exit zone):
𝑝 𝑦
• = 𝐶 + 𝑅 𝑒 +𝜇𝜆 ; 𝐶 + is the value of constant C after the neutral point
2𝐾
𝑝𝑓 𝜎𝑥𝑓
• Again, 2𝐾 = 1 − ; 𝑝𝑓 roll pressure at the exit point
2𝐾
𝜎𝑥𝑓 𝑡𝑓
• 1− = 𝐶 + 2𝑅
2𝐾
• The non-dimensional roll pressure (p/2K) in the regions before and after the
neutral point can be obtained as the following:
𝑝 2𝑦 𝜎𝑥
• = 1 − 2𝐾𝑖 𝑒 𝜇 𝜆𝑖−𝜆
2𝐾 𝑏𝑒𝑓𝑜𝑟𝑒 𝑡𝑖

𝑝 2𝑦 𝜎𝑥𝑓
• = 1− 𝑒 𝜇𝜆
2𝐾 𝑎𝑓𝑡𝑒𝑟 𝑡𝑓 2𝐾
26
 Rolling – simple analysis
• Roll pressure distributions for the entry and exit zones can be simplified:
2 𝑡 2 𝑡 𝐾𝜀 𝑛
– 𝑝𝑒𝑛𝑡𝑟𝑦 = 𝜎𝑓𝑎𝑣𝑔 𝑒 𝜇(𝜆𝑖 −𝜆) ; 𝑝𝑒𝑥𝑖𝑡 = 𝜎𝑓𝑎𝑣𝑔 𝑒 𝜇𝜆 𝜎𝑓𝑎𝑣𝑔 =
3 𝑡𝑖 3 𝑡𝑓 𝑛+1

𝑅 𝑅
– 𝜆=2 tan−1 𝜃
𝑡𝑓 𝑡𝑓

• At neutral point, both pentry and pexit will be same (𝜆 = 𝜆𝑛 ):

2 𝑡 2 𝑡
– 𝜎𝑓𝑎𝑣𝑔 𝑒 𝜇(𝜆𝑖 −𝜆𝑛 ) = 𝜎𝑓𝑎𝑣𝑔 𝑒 𝜇𝜆𝑛
3 𝑡𝑖 3 𝑡𝑓

𝑡𝑖 𝑒 𝜇(𝜆𝑖 −𝜆𝑛 )
– = = 𝑒 𝜇(𝜆𝑖 −2𝜆𝑛 )
𝑡𝑓 𝑒 𝜇𝜆𝑛

𝑡𝑓 𝜆𝑛 𝑡𝑓
– 𝜃𝑛 = tan
𝑅 2 𝑅

1 1 𝑡𝑖 𝑅 𝑅
– 𝜆𝑛 = 𝜆𝑖 − ln 𝜆=2 tan −1 𝜃
2 𝜇 𝑡𝑓 𝑡𝑓 𝑡𝑓

27
 Pressure distribution in rolling

px lagging px leading

• Roll pressure (𝑝) increases continuously from the entry point (𝜃𝑖 )
until the neutral point (𝜃𝑛 ) is reached.
In the lagging zone pressure pulls the billet
• After that the roll pressure reduces continuously in whereas in the leading zone both friction
and pressure push it it back. Hence, larger

• Peak pressure is the highest at the neutral point

the lagging zone the better.

• Peak pressure increases with increasing coefficient of friction

• Applying back/front tension will reduce peak pressure and will also
shift the neutral position towards the exit point
28
 Roll separating force and driving torque
• Total force trying to separate the rolls can be obtained by integrating
the vertical component of the force acting on the roll-strip interface
– Vertical components: (𝑝𝐶𝑜𝑠𝜃. 𝑅𝑑𝜃 + μ𝑝𝑆𝑖𝑛𝜃. 𝑅𝑑𝜃)
– μ𝑝𝑆𝑖𝑛𝜃. 𝑅𝑑𝜃 is very small than 𝑝𝐶𝑜𝑠𝜃. 𝑅𝑑𝜃
• As the entry angle is normally small, the contribution of the roll-
strip interface friction is negligible in the vertical direction
𝜃𝑖 𝜃𝑖
• 𝐹= 0
𝑝𝑅 𝑐𝑜𝑠𝜃 𝑑𝜃 ≃ 0
𝑝𝑅 𝑑𝜃
𝜃𝑛 𝜃𝑖
• 𝐹= 0
𝑝𝑒𝑥𝑖𝑡 𝑅 𝑑𝜃 + 𝑝
𝜃𝑛 𝑒𝑛𝑡𝑟𝑦
𝑅 𝑑𝜃 [Needs to solve numerically]
• Driving torque: driving torque required to overcome the torque
exerted on the rolls by the interfacing friction force
𝜃𝑖 2 𝑑𝜃 𝜃𝑛 2 𝑑𝜃 𝜃𝑖 2 𝑑𝜃
• 𝑇= 0
𝜇𝑝𝑅 =− 0
𝜇𝑝𝑎𝑓𝑡 𝑅 + 𝜃𝑛
𝜇𝑝𝑏𝑒𝑓 𝑅

𝑡𝑖 −𝑡𝑓 𝑡𝑓 𝜆𝑛 𝑡𝑓
• 𝜃𝑖 = ; 𝜃𝑛 = tan
𝑅 𝑅 2 𝑅

• Driving power per roll 𝑃𝑅; 𝑃𝑅 = 𝑇𝜔

29
 Rolling – simple analysis
• Rolling force (also called roll-separating force), F = (area under the
pressure vs. contact length curve) x (width of sheet) :
𝜃 𝜃𝑛 𝜃
–𝐹= 0
𝑝𝑑𝐴 = 0
𝑤𝑝𝑒𝑥𝑖𝑡 𝑅𝑑𝜃 + 𝜃𝑛
𝑤𝑝𝑒𝑛𝑡𝑟𝑦 𝑅𝑑𝜃
• Driving torque is required to overcome the friction exerted on the
roll by the interfacial friction force
𝜃 𝜃𝑛
– Torque 𝑇 = 𝜃𝑛
𝑤𝜇𝑝𝑒𝑛𝑡𝑟𝑦 𝑅 2 𝑑𝜃 − 0
𝑤𝜇𝑝𝑒𝑥𝑖𝑡 𝑅 2 𝑑𝜃

30
 Rolling – Average rolling force
• Average rolling force
2 𝜇𝐿
• 𝐹𝑎𝑣𝑔 = 𝐿𝑤𝑝𝑎𝑣𝑔 = 𝐿𝑤 𝜎 1+
3 𝑓𝑎𝑣𝑔 2𝑡𝑎𝑣𝑔
𝐾𝜀𝑛
• 𝜎𝑓𝑎𝑣𝑔 =
𝑛+1
• 𝑡𝑎𝑣𝑔 = 0.5(𝑡𝑖 + 𝑡𝑓 ); 𝐿 = 𝑅Δ𝑡
𝜃 𝜃𝑛
• Torque 𝑇 = 𝜃𝑛
𝑤𝜇𝑝𝑒𝑛𝑡𝑟𝑦 𝑅 2
𝑑𝜃 − 0
𝑤𝜇𝑝𝑒𝑥𝑖𝑡 𝑅 2
𝑑𝜃
• Power 𝑃 = 𝑇𝜔

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 Example - 1
• A 75 mm thick by 250 mm wide slab of AISI 4135 steel is being
coldrolled to a thickness of 60 mm in a single pass. A two-high rolling
mill with 750 mm diameter rolls made of tool steel is available for
this task. The rolling mill has a power capacity of 5 MW per roll. The
rolls rotate at a constant angular speed of 100 rev/min. The steel
work material has the following flow curve at the rolling
temperature: MPa. Assume the coefficient of friction µ = 0.2. Is the
available rolling mill adequate for the desired operation?

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 Example - 1
• The rolling mill is adequate if the required power for the operation is
less than or equal to the available power.
• Roll separating force,
2 𝜇𝐿
• 𝐹𝑎𝑣𝑔 = 𝐿𝑤𝑝𝑎𝑣𝑔 = 𝐿𝑤 𝜎 1+
3 𝑓𝑎𝑣𝑔 2𝑡𝑎𝑣𝑔

• 𝐿 = 𝑅Δ𝑡 = 0.075 m
• tavg = 0.5 (0.075+0.060)= 0.0675 m
𝐾𝜀𝑛
• 𝜎𝑓𝑎𝑣𝑔 = = 779 Mpa
𝑛+1
• 𝐹𝑎𝑣𝑔 = 18.74 MN
• Power 𝑃 = 𝑇𝜔 = 7.3 MW
• Power available is only 5MW, so this motor is not good enough

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 Example - 2
• A strip with a cross-section of 150 mm x 6 mm is cold rolled with a
20% reduction in the cross-section area in a single pass. Diameter of
steel rolls is 400 mm. Shear yield stress (K) of the material at entry
and exit point is 0.35 kN/mm2 and 0.4kN/mm2. Coefficient of friction
is 0.1 (cold rolling). Please find:
– Position of neutral point
• Solution:
– Final thickness (4.8 mm)
– Average shear yield stress : (initial K +final K)/2 …(0.375 kN/mm2)
– Total angle extended (Angle of bite) >> (4.5 degree)

𝑡𝑓 𝜆𝑛 𝑡𝑓
𝜃𝑛 = tan
𝑅 2 𝑅

1 1 𝑡𝑓 𝑅 𝑅
𝜆𝑛 = ln + 𝜆𝑖 𝜆𝑖 = 2 tan−1 𝜃
2 𝜇 𝑡𝑖 𝑡𝑓 𝑡𝑓 𝑖

34
 Example (3.1)
• A strip with a cross-section of 150 mm x 6 mm is cold rolled with a
20% reduction in the cross-section area in a single pass. Diameter of
steel rolls is 400 mm. Average shear yield stress (K) of the material
is 0.375 kN/mm2. If coefficient of friction is 0.1 (cold rolling) and roll
speed is 30 m/min. Find: roll separating force and power required?

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 Role of Friction on roll pressure
• With higher µ, the roll pressure are
higher at all points of contact area
except at entry and exit points
• Therefore, the total load on the rolling
mill increases
• Effect of back tension and forward
tension is to reduce the roll pressure at
all points of contact area
• Front and Back-tension at entry and
exit point also reduces to (𝜎0′ -𝜎𝑏 ) and
(𝜎0′ -𝜎𝑓 )
• Location of neutral section also shifts
on application of 𝜎𝑏 and 𝜎𝑓

*BL Juneja – Metal forming, Chapter 7 36

 Effect of roll diameter on roll pressure*
• Larger roll radius (R1) results in
larger length of contact (L1)
• Area of pressure diagram in case
of R1 is much larger than that
with R2.
• Rolling load increases with the
increases in roll diameter
• In case of cold rolling of thin
sheets, larger loads are
encountered, which can be
reduced by:
– Reducing friction
– Applying forward and back
tension
– By using smaller roll diameter

*BL Juneja – Metal forming, Chapter 7 37

 Smaller or larger roll mill
• Smaller-diameter rolls produce less
length of contact for a given reduction
and therefore require lower force and
less energy to produce a given change
in shape.
• The smaller cross section, however,
provides reduced stiffness, and the
rolls are prone to flex elastically
because they are supported on the
ends and pressed apart by the metal
passing through the middle
• Four-high and cluster arrangements
use backup rolls to support the
smaller work rolls.

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