Module 8 1

Rolling
Principle of the process

Structure

Process modeling

Defects

Design For Manufacturing (DFM)

Process variation
Metal
forming
handout 8 b 2
Rolling Process: Mechanics Analysis
Two opposite rolls and a piece of material flows between
them. The shape of rolls can be designed in a different form
to construct a product with different cross sections.
handout 8 b 3
Objectives of mechanics analysis
a. Physical
phenomenon
b. Torque
c. Power
d. Productivity
System
parameters
Operating
parameters
handout 8 b 4
Physical phenomenon
Volume flow rate conservation
f f f
v w t v w t
0 0 0
Spreading: Volume before
rolling = the volume after rolling
f f f
L w t L w t
0 0 0
L
w
t
f
v v
0
f
t t d Draft
0
,
handout 8 b 5
Vo < Vr < Vf
No-slip point
Work velocity = Roll velocity
Slipping
Slipping
( ) /
f r r
Forward Slip v v v
handout 8 b 6
For the rolling process, the true strain is:
f
t
t
0
ln
The average flow stress is the same expression, i.e.
n
k
Y
n
f
+

1

handout 8 b 7
It is the friction between the work and the roll that
drives the workflow between two rolls.
The friction force is developed based on
(1) coefficient of the friction and
(2) compression force of rolls
No-slip point
Greater
Friction Force
Lesser
Friction Force
handout 8 b 8
Condition to roll- Coefficient of the friction
draft, d = |t
f
-t
0
|: d
max
R d
2
max

Max.
Possible
Draft
Friction causes Rolling
If Friction=0, then draft=0, means NO ROLLING
Radius of the roll
Friction coefficient
handout 8 b 9
The pressure varies along the
contact length
Condition to roll- Power to drive the roll and work piece
Roll Force (F) Integrating
unit roll pressure over
roll work contact area

L
pdL w F
0
handout 8 b
Contact length
) (
0 f
t t R L
Contact force

L
pdL w F
0
wL Y F
f

Power
NFL P 2
FL T 5 . 0
Torque
N: rotation
speed of the roll,
rev / min
d
Power is a function of D. Increase of D leads to increase of P
Condition to roll- Power to drive the roll and work piece
When the required power (d) is greater than the supplied
power, the rolling of a work piece with d is not possible.
Therefore, the required power = supplied power will lead to
a critical draft d or maximum d.
Criterion 1:
R d
2
max

Criterion 2: required power = supplied power
max
d
The actual maximum draft for a rolling system is the smaller
one computed from the two criterions above.
handout 8 b 12
Example:

A 10-in. wide, 1.0-in thick plate is to be reduced in a
single pass in a two-high rolling mill to a thickness of 0.8
in. The roll has a radius = 20 in., and its speed = 50
ft/min. The work material has a strength coefficient =
35.000 lb/in.
2
and a strain hardening exponent = 0.2.
Determine (a) roll force, (b) roll torque, and (c) power
required to accomplish this operation.
handout 8 b 13
Given: rolling, t0=1.0 in., tf=0.80 in., w=10.0 in., R=20
in., vr=50 ft/min, flow curve n=0.20 and K=35,000 lb/in2.
Find: (a) F, (b) T, (c) HP.
Draft d=1.0-0.8=0.2 in.
Contact length L = (200.20)
0.5
= 2.0 in.
True strain = ln (1.0/0.8) = ln 1.25= 0.223
Average flow stress
Y
f
= 35,000(0.223)
0.20
/1.20 = 21,607 lb/in
2

Rolling force F = 21,607(10)(2) = 423,149 lb
handout 8 b 14
Torque T = 0.5(432,149)(2.0) = 432,149 in-lb.
N = (50 ft/min)/(220/12) = 4.77 rev/min.
Power P=2 (4.77)(432,149)(2) = 25,929,940 in-lb/min

HP = (25,929,940 in-lb/min)/(396,000) = 65.5 hp