ADDIS ABABA SCIENCE AND

TECHNOLOGY
UNIVERSITY

COLLEGE OF ELECTRICAL AND MECHANICAL

ENGINEERING
DEPARTMENT OF MANUFACTURING ENGINEERING

GROUP ASSIGNMENT - ONE

COURSE INFORMATION:-
 COURSE TITLE: METAL FORMING
TECHNOLOGY
COURSE CODE: Meng 5201

MANUFACTURING OF I BEAM BY ROLLING MILL

GROUP MEMBERS
NAME ID NO.
1. KEBEDE TEKA ETS 0647/08
2. FITSUM ARARSA ETS 0454/08
3. SISAY DEMISSIE ETS 1012/08
4. SHIMELESE ESHETU ETS 1002/08
5. SOLOMON JEMBERU ETS 1022/08
6. SINTAYEHU KETEMA ETS 1009/08
Submitted to: ISRAEL ZELALEM
Submission date: 04/01/2018
 Introduction

Forging is a manufacturing process involving a shaping of metal using localized compressive

forces. The blows are delivered with a hammer (often a power hammer) or a die. Forging is often

classified according to the temperature at which it is performed: Cold forging (a type of cold

working),Hot forging or warm forging(a type of hot working).For the latter two, the metal is

heated usually in a forge. The forging has been done by smiths for millennia; The traditional

products were kitchenware, hardware ,hand tools, edged weapons, cymbals and jewelry. Since

the industrial revolution, forged parts are widely used in mechanisms in machines where ever a

component high strength; such forgings usually requires further processing(such as machining)

to achieve a finished part. Today, forging is a major world wide industry. Due to this fact forging

is also used to manufacture the “I” beam. An I beam is a beam with an I shaped cross section.

The Horizontal elements of the “I” are known as flanges, while the vertical element is termed the

“Web”. I-beams are steel structures widely used in construction industry. It is an important part

of any type of construction. I-beams are commonly made of structural steel. Different sizes of I-

beams are required depending on various light & heavy applications. The vertical element of the

I beam resists a shear forces while the horizontal elements of the “I” Beam resist most of the

bending moment experienced by the beam. The method of producing an “I” beam, as rolled

from a single piece of a steel, was patented by Alphonse Halbou of the company “Forges de la

Providence” in 1849.Bethlehem Steel was a leading supplier of rolled structural steel of various

cross sections in American Bridge and Skyscraper work of the mid twentieth century. Today

,Rolled cross sections have been partially displaced in such work by fabricated cross sections.
1.2HISTORICAL BACKGROUND

The I profile was born in the railway field through the realization of the train tracks,

originally constructed under form of wood prismatic elements with a metal band at their extrados

having the function of a rolling plane. For durability reasons, in 1789 these types of profiles were

replaced by the English engineer William Jessop with cast-iron elements characterized by an

embryonic I section composed of two bulbs and a web. Technological reasons linked to the low

productivity of the production process, together with the reduced tensile strength of the material,

strongly decreased their use, so as to be completely displaced by the advent of the first hot-rolled

steel products. Starting from the T-section, the first iron or laminated steel rails suffered a fast

evolutionary process, early attaining the current configuration of the wide flange I profile, known

as Vignoles rail and devised in 1831 by the American colonel Robert L. Stevens .Almost

simultaneously to the railway applications, the I profile was introduced in the shipbuilding and

civil fields. The pioneer in both fields was the Scotsman Sir William Fairbairn who, taking profit

of the scientific consultant activity given by the English engineer Eaton Hodgkinson, performed

in the 30's theoretical and experimental investigations aimed at choosing the optimal profile to be

used for both cast iron full beams for railway crossings and hot-rolled steel stiffening ribs for

hulls of boats. The results achieved by Fairbairn and Hodgkinson were also usefully employed in

the civil construction sector, in particular for the erection of long-span bridges. From the mid-

nineteenth century, with the development of the hot-rolling production process, the I profiles

were used in the construction of residential and industrial buildings by replacing both the

previously used wooden rectangular or circular members and the cast iron T-sections, the latter

introduced in early 1800 by James Watt .

1.3. objectives of the study

In this paper it is tried to show the manufacturing process of the I beam using the roll forming

process. It includes :-

 the structural analysis of the I beam in the process appropriate procedures .

 the justifications required to manufacture this material specific standardizations are

listed in this paper for the purpose of manufacturing the desired material.

 The process plan in the production of I-beam

 The tools and equipment used in the process

2. Methodology

Method of Analysis

Most of the time the I beam is produced using the Roll forging process so in this paper we will

be using the analysis involved in this process.

Which will include the :-

 stress Analysis

 Strain determining

 Since the beam is a huge mass it will be hard to use the cold working process instead hot

working will be easier in this process. So dealing with the metal heating is also needed.

 The beam is mainly preluded to a highly stress concentrated loads the material

determination will also be there in the Manufacturing process.

The following considerations will be included

 The material size

 Standardized Specifications of the Materials

 The Design : In this research since the I-beam is used it will have different designing

types like the tapered flanges, Intermediate, parallel and ...etc. For this we have chosen

the parallel Flange I beam type.

So the I beam has a standardized specifications and the material which is need to be used which

is the steel. In order to justify The steel in this process is used because it can give the ability for

the I-beam to withstand a better load and a good tensile strength rather than other ferrous metals

like the cast iron.For this reason we have chosen the steel to be used for this product.

3. ANALYSIS
 3.1 Analysis of the Beam

In the process of manufacturing I-beam a hot rolling will be used and the values of the I-beam

can be calculated in the standardized tests of international laboratories. So we will leave the

calculation by taking the values directly from the journals published by them.

For this purpose we will use the standards of American Institute of steel construction “AISC”.

So the product that we choose have the following designations.

Type Beam Flange Web Flange Weight Cross Moment of

height(in) width thickness thickness (lb/ft) section inertia(cm4)
(in) (in) (in) area(in2)
W6X16 6.28 4.03 0.26 0.405 16 4.74 0.223

As it is seen in the above table the I-beam chosen for this research will the standard W6X16. In

which “W” stands for wide flange , “6” represents the depth in inches (nominal height of the

wide flange to the outer face of the flange while 16 is representing the weight of the wide flange

I-beam in pound per inches.

3.2 Analysis of The Rolling Mills

fig. I beam shaping by rolling

cylinder.
 As the bloom pass through the rolling mills as shown in the above figure , since the side mills

only give support to the bloom with out applying a force. Then ,the bloom will be subjected to a

force which will be exerted by the upper and lower mills as shown in the figure below.

As shown in the above figure power is applied to a rolling mill by applying a torque to the

rolls by means of strip tension. The power is extended principally in four ways ;

1. The energy needed to deform the metal

2.The energy needed to overcome frictional forces in the bearings

3.The energy lost in the pinions and power transmission system , and

4. Electrical losses in the various motors and generators. Loses in the wind up reel and uncoiler

must also be considered .

The total rolling load is distributed over the arc of contact in the typical friction hill pressure

distribution. However, the total rolling load can be assumed to be concentrated at a point along

the arc of contact at a distance a from the line of centers of the rolls. In calculating the torque the

problem is mainly how to calculate this moment arm . It is usually practice to consider the ratio
of the moment arm “a” to the project length of the arc of contact.

λ = a/ Lp ˭ a
[R(ho-hf)]1/2

A typical value of λ is 0.4 hot rolling .The torque is equal to the total rolling load multiplied by

the effective moment arm, and since there are two work rolls ,the torque is given by

Mt = 2Pa

During one revolution of the top roll the resultant rolling load P moves along the circumference

of a circle equal to 2Πa. Since there are two work rolls involved , the work done is equal

Work = 2(2Πa)P

since power is defined as the rate of doing work , i.e. , 1W=1Js-1, the power (in watts) needed to

operate a pair of rolls revolving at N Hz(=s-1) is given by

W=4ΠaPN

Where P is in Newtons and “a” is in meters. The equation express the power required in

deforming the metal as it flows through the roll gap. The power needed to overcome friction in

the bearings and the pinions must be determined separately. The same basic equation for power

holds for hot rolling , with the important condition that the equations which were given for

determined the effective moment arm in cold rolling are not applicable in hot rolling .A

procedure for determining the moment arm in hot rolling based on the work of sims, is given in

detail by Larke .although the calculations are straight forward ,they are too detailed for inclusion

here.
A 170X104 mm bloom steel is hot rolled in web thickness from 104 to 6.604 mm , the rolls are

1.2 m in diameter and operate at 60 rpm. The uni axial flow stress for the steel can be expressed

as ơ = 162ɛ0.2(Mpa), for this value now we calculate the rolling load and the power required for

this hot reduction.

Ɛ1 = ln(104/6.604) = 2.757
r = 104 – 6.604 = 0.936
104
R/hf = 600/ 6.604 =90.854

ɛ
ơ 0 = ( k⌠ ɛndɛ ) / ɛ1 =
0 (kɛn+1) / ɛ1(n+1) = (kɛ1) / n+1

ơ0 = 162(2.757)0.2 / 1.2 = 165.36Mpa

Also calculate the rolling load (P) for hot-rolling ;

Rolling load, (P) = kbLp (1.31 + 0.53Lp

(h0hf)1l2
= (2/√3) (165.36)(0.104)(√(0.6(0.104–0.0604))*(1.31 + 0.53*√(0.6(0.104 -0.0604)
(|0.104*0.0604)1/2

= 3.212 ( 2.392 )

= 7. 68 MN
Besides, calculate power ;

Power, (W) = 4ΠaPN

where, a = λLp ; for hot forging λ = 0.5 N = 60 s-1 = 1s-1

60
a = 0.5(√(0.6(0.104 – 0.0604))

a = 0.0809 m

Now, Power(W) = 4Π(0.0809)( 7.68*106)(1) Js-1

W = 7.808 MW

4. MANUFACTURING PROCESS PLAN

In the previous chapter of this research it is selected the rolling mill specification. The next

step is the industrial processes. It is generalized in the lower table

Process input function

Rolling Process bloom Getting required shape
Shot Blasting Rolled steel, polishing material Clean & strengthen the metal
Heat Treatment Heat, rolled steel Increase ductility and toughness
Final Product - Checking size, quality, shape

The heated bloom will be rolled again and again until it gets its required size. In this stage the

other thing which will be considered is the removal of oxides by pressurized air on the surface of

the bloom. In the place of the pressurized air we can also used the water, steam or any other fluid

with a good flowability. The other name of this process is the hammering effect. In the rolling

process in which our uncooled bloom will be passing through the rolls of the rolling machine and

get the required minimized size of the beam. It is a process of reducing the thickness or changing
the cross section of a long work-piece by Compressive forces applied through set of rolls. After

getting the required size of the I-beam the next step is the short blasting . It is a process used to

clean ,strengthen (peen) or polish metal. So in the I-beam after the rolling process is completed

the short or shot blasting will take place in order to give the steel strength and removing cracks

stocks and other defects appeared on the I beam during the former forging processes. The Next

one is the heat treatment where the I-beam this process can be used to harden the I-beam. It is

done by raising the temperature of the I-beam from 760 to 870 C then cooling it by inserting it

water to Oil rapidly. Such hardening treatments, which form martensite, set up large internal

strains in the metal, and these are relieved by tempering, or annealing, which consists of

reheating the steel to a lower temperature. Tempering results in a decrease in hardness and

strength and an increase in ductility and toughness. The steel is then allowed to cool in air

through the temperature range of martensite formation, which for most steels is the range from

about 288° C (about 550° F) to room temperature.

In austempering the steel is quenched in a bath of metal or salt maintained at the constant

temperature at which the desired structural change occurs and is held in this bath until the

change is complete before being subjected to the final cooling. Then final cooling process of

cooling of heating process takes place after that we can get our final product.

4.1 The Required Tools In The I-beam Production

Basic tools used in the rolling process of an I beam includes:

 Conveyor

 Pneumatic Crane

 Product Holder
 There many tools used in this process. The rolling machines by itself have tools which will be

adjusted to it. Solid rolls are essential to the iron and steel industries. The heat-resistant and

deform resistant cemented carbide can mill steel heated to approximately 1000ºC. This

contributes to the high-efficiency rate in the production of steel. Our ring rolls have been adopted

in many variant rod wire and steel bar production line. So the I-beam is a form bar the ring rolls

will be for our project .The other tools are the supporting to the long beam as a support on the

rolling machine. To list the additional tools the crane mechanisms used to lift the I-beam.

4.2 Equipment and Machineries

The machineries and equipment that are mainly used in this process are given below:

 Rolling Mills

 Abrasives

 Furnace

 Coolant Reservoir

 Heat and Mass Measuring Gauges

The machines which will be used in the beam production depends on the steps involved in

the manufacturing process. So the machine which will come first is the forging machine which

will turn the continuous casting ingots in a rectangular blooms through a required size.

The rolling machine consist of the high heat resistance rolls and includes pressure applying

hydraulics connected to the rolls. Then the next machine will be the shot blasting machine in

which the rolled I-beam and will be polished and strengthened. The final process which is the

heat treatment so the machine which will be used is related to the heat treatment process. When

we come to the equipments in the hot rolling process.

5. Two and Three Dimensional Drawing For an I Beam

For the purpose of clarity we have shown the views of our product separately

With out the conventional drawing projections.

Fig. Multi-view Projections of the I-beam

 Fig. Isometric view of the I beam

SUMMARY

In this project it has been discussed the production of I-beam with hot rolling process. In

the project we have discussed the process type ,the analysis made on the rolling mills.

The manufacturing process plan. The tools and equipments used in the production

process which includes the machineries used. In general it is tried to produce an I-beam

which meet the international standards specified. That means AISC -American Institute

of Steel Construction by taking a conventional dimension of an I beam with the standard

W6X16.So this consists the production process for the I beam standard of the former

specifications.
Reference

1. George E. Dieter, “Mechanical Metalluurgy”, McGraw-Hill Pub., 1998

2. William F. Hosford and Robert M. Caddle, Metal Forming Mechanics and Metallurgy, 3rd

edition ,Cambridge University, 2007

3. ASM Handbook, “Forming and Forging”, ASM International, Ohio, 1988

4. Courtney, T.H, “Metalwork Technology”, London, John Murray, 1972.