Rolling

Deformation Processing Rolling
ver. 1
ME 6222: Manufacturing Processes and Systems

Prof. J.S. Colton
Overview
Process
Equipment
Products
Mechanical Analysis
Defects

Prof. J.S. Colton
Process

Prof. J.S. Colton
Process

Prof. J.S. Colton
Process

Prof. J.S. Colton
Ring Rolling

Prof. J.S. Colton
Equipment

Prof. J.S. Colton
Equipment

Prof. J.S. Colton
Products

Prof. J.S. Colton
Products
Shapes
I-beams, railroad tracks
Sections
door frames, gutters
Flat plates
Rings
Screws

Prof. J.S. Colton
10
Products
A greater volume of metal is
rolled than processed by any
other means.

Prof. J.S. Colton
11
Model flat sheet

zero
slip
point
hb
xb
vb
R
vb < vR < vf
vf
hf
xf
Exit
Entrance
vR
Prof. J.S. Colton
12
Plane strain analysis

Entrance
Exit
h + dh
h + dh
h
x + dx
dx
h
x x + dx
dx
p
Prof. J.S. Colton
p
13
Equilibrium
(top) = entry, (bottom) = exit
( x + d x ) (h + dh ) 2 pR d sin 2pR d cos = 0

Simplifying and ignoring HOTs
d ( x h )
= 2 pR (sin m cos )
d

Prof. J.S. Colton
14
Simplifying
Since << 1, then sin = , cos = 1
d ( x h )
= 2 pR ( m )
d
Plane strain, von Mises
p x = 1.15 Y flow Y flow

Prof. J.S. Colton
15
Differentiating
Substituting
[(
) ] = 2 pR ( m )
h
d p Yflow
d
or

p
d
Y flow

1 h = 2 pR ( m )

Y flow

Prof. J.S. Colton
16
Differentiating
d
d p p
h
h = 2 pR ( m )
Y flow
Y flow
+
1
d
Y flow
d Y flow

rearranging
d p

d Y flow
Y flow
2R
( m )
=
h

Prof. J.S. Colton
17
Thickness
h = h f + 2 R (1 cos )
from the definition
of a circular segment
R
hb h f
hb
2
hf
2
or, after using a Taylors series expansion, for small
cos = 1
h = h f + R
2
2!
4
4!

Prof. J.S. Colton
18
Substituting and integrating
d
Y flow

=
p
Y flow
2R
f
+ R
(
)
m
d
2
p
h
R
R
1
+ ln C
ln
tan
= ln m 2
hf
Y f
R
hf

Prof. J.S. Colton
19
Eliminating ln()
h
exp(m H )
p = C Y flow
R
R
R
1
tan
H =2
hf
hf

Prof. J.S. Colton
20
Entry region
at = , H = Hb , and p =(Yflow xb)
R
C=
exp(H b )
hf
xb
p = Y flow
h
exp( [H b H ])
hb
R
R
1
tan
Hb = 2
hf
hf
R
R
1
tan
H =2
hf
hf

Prof. J.S. Colton
21
Exit region
at = 0, H = Hf =0, and p =(Yflow xf)
R
C=
hf
h
xf ) exp(H )
p = (Y flow
hf
R
R
1
H =2
tan
hf
hf

Prof. J.S. Colton
22
Effect of back and front tension

maximum pressure
pressure
Y xf
Y xb
distance
Prof. J.S. Colton
23
Average rolling pressure per unit width
pave,entry
1
Hb H n
1
=
Hb Hn
Hb
Hn
1
Hn H f
Hb
entry
dH ; pave ,exit
Hn
1
pentry dH =
Hb H n
Hn
Hf
pexit dH =
1
=
Hn H f
Hb
xb
Y flow
Hn
1
Hn H f
Hf
exit
dH
Hn
h
exp( [H b H ]) dH
hb
Hn
h
xf ) exp(H ) dH
(
Y flow
Hf

Prof. J.S. Colton
24
Average rolling pressure - entry

1
pave (entry ) =
Hb H n
Hb
xb )
(
Y flow
Hn
h
exp( [H b H ]) dH
hb
Taylors series expansion

0
2
0
3
x
x
x
+
+L+
=
exp(x ) = 1 + x +
2! 3!
n!
k =0
xk
k!
xb )
(
Y flow
pave (entry ) =
h (1 + [H b H ]) dH
hb (H b H n )
Hb
Hn

Prof. J.S. Colton
25
Average rolling pressure - entry

xb )
(
Y flow
pave (entry ) =
h (1 + [H b H ]) dH
hb (H b H n )
Hb
Hn
R
R
1
tan
H =2
hf
hf
h = h f + R 2
solve numerically
Prof. J.S. Colton
26
Average rolling pressure - exit

1
pave (exit ) =
Hn H f
Hn
xf
Y flow
Hf
h
exp(H ) dH
hf
Taylors series expansion

0
2
0
n
x
x
x
+
+L+
=
exp(x ) = 1 + x +
2! 3!
n!
k =0
xk
k!
xf )
(
Y flow
pave (exit ) =
h (1 + H ) dH
h f (H n H f )
H
Hn

Prof. J.S. Colton
27
Average rolling pressure - exit

xf )
(
Y flow
pave (exit ) =
h (1 + H ) dH
h f (H n H f )
H
Hn
R
R
1
tan
H =2
hf
hf
h = h f + R 2
solve numerically
Prof. J.S. Colton
28
Rolling force
F = pave,entry x Areaentry + pave,exit x Areaexit

Prof. J.S. Colton
29
Force
An alternative method
F=
w pentry R d + w pexit R d
0
again, very difficult to do.

Prof. J.S. Colton
30
Force - approximation
F / roller = L w pave
L Rh
h = hb - hf
pave
have
= f
L
Prof. J.S. Colton
31
Derivation of L
circular segment
h = h f + 2 R (1 cos )
0
Taylors expansion
cos = 1
h = h f + R
2!
hb
2
R
hb h f
hf
4!
R = L
Prof. J.S. Colton
32
Derivation of L
setting h = hb at = , substituting, and rearranging
L
hb h f = h = R
R
or
L = R h

Prof. J.S. Colton
33
Approximation based on forging

plane strain von Mises
pave
= 1.15 Y flow 1 +
2have
average flow stress:
due to shape of element

Prof. J.S. Colton
34
Small rolls or small reductions

have
=
>> 1
L
friction is not significant ( -> 0)
pave
= 1.15 Y flow 1 +
2have
0
pave = 1.15 Y flow

Prof. J.S. Colton
35
Large rolls or large reductions

have
<< 1
L
Friction is significant (forging
approximation)
pave
= 1.15 Y flow 1 +
2have

Prof. J.S. Colton
36
Force approximation: low friction

have
>> 1
L
roller
= 1.15 LwY flow

Prof. J.S. Colton
37
Force approximation: high friction

have
<< 1
L
F
= 1.15 LwY flow 1 +

roller
2have

Prof. J.S. Colton
38
Zero slip (neutral) point

Entrance: material is pulled into the nip
roller is moving faster than material
Exit: material is pulled back into nip

roller is moving slower than material
vf
vb
vR
material
pull-in
vR
vR
material
pull-back

Prof. J.S. Colton
39
System equilibrium
Frictional forces between roller and
material must be in balance.
or material will be torn apart
Hence, the zero point must be where

the two pressure equations are equal.
hb
exp(H b )
=
= exp( (H b 2 H n ))
hf
exp(2 H n )

Prof. J.S. Colton
40
Neutral point
1
1 hb
Hn =
H b ln
2
hf
n =
H
tan n
2
R
hf
h f
R

Prof. J.S. Colton
41
Torque
paveA
L Rh
L/2
R
h = hb - hf
=0
Froller = pave A
Froller
n
T=
Torque / roller = r Froller
wpR 2 d
entry
wpR 2 d
exit
Froller L
L
= Froller =
2
2

Prof. J.S. Colton
42
Power
Power / roller = T = FrollerL / 2
= 2N
N = [rev/min]

Prof. J.S. Colton
43
Processing limits
The material will be drawn into the nip if the
horizontal component of the friction force (Ff) is
larger, or at least equal to the opposing horizontal
component of the normal force (Fn).
F f cos Fn sin
Ff
h/2
F f = Fn
tan =
Fn
= friction coefficient

Prof. J.S. Colton
44
Processing limits
Also
cos =
h
2 = 1 h
R
2R
and
h << R
sin = 1 cos 2
0
h h
sin = 1 1 +

2R 2R
h
R
tan =
2
h h
1
+
R 2R
sin
h
R
h
h
R h
R

Prof. J.S. Colton
45
Processing limits
So, approximately
(tan )
h
= =
R
2
Hence, maximum draft
hmax = 2 R
Maximum angle of acceptance
max = = tan 1
Prof. J.S. Colton
46
Cold rolling
(below recrystallization point)
strain hardening, plane strain von Mises
2 flow = 1.15 Y flow
K
= 1.15
n +1
n


Prof. J.S. Colton
47
Hot rolling
(above recrystallization point)
strain rate effect, plane strain - von Mises
Average strain rate
V
h
R
b
&
= = ln
t
L hf
2 flow = 1.15 Y flow
m
&
= 1.15 C

Prof. J.S. Colton
48
Example 1.1
Cold roll a 5% Sn-bronze
Calculate force on roller
Calculate power
Plot pressure in nip (no back or forward
tension)

Prof. J.S. Colton
49
Example 1.2
w = 10 mm
hb = 2 mm
height reduction = 30% (hf = 0.7 hb)
hf = 1.4 mm
R = 75 mm
vR = 0.8 m/s
mineral oil lubricant ( = 0.1)
K = 720 MPa, n = 0.46
Prof. J.S. Colton
50
Example 1.3
Maximum draft:
hmax = 2R
= (0.1)2 75 = 0.75 mm
hactual = hb - hf = 2 - 1.4
= 0.6 mm

Prof. J.S. Colton
51
Example 1.4
Maximum angle of acceptance
max = tan-1 = tan-1(0.1) = 0.1 radian
(hb h f )
R
(2 1.4)
75
= 0.089 rad = 5.12o

Prof. J.S. Colton
52
Example 1.5
Roller force: F = L w pave
L = (Rh)0.5 = [75 x (2-1.4)]0.5
= 6.7 mm
w = 10 mm
have = (hb+hf) / 2 = 1.7 mm
have / L = 1.7 / 6.7 = 0.25 < 1
friction is important
F
= 1.15 LwY flow 1 +

roller
2have

Prof. J.S. Colton
53
Example 1.6
hf
f = ln
hb
1.4
= ln
= 0.36
2 flow = 1.15 Y = 1.15

720 (0.36)
= 1.15
1.46
K nf
n +1
0.46
= 354 MPa

Prof. J.S. Colton
54
Example 1.7
= 1.15 LwY flow 1 +

roller
2have
3
3
6
= 6.7 10 10 10 354 10
F
0 .1 6 .7
1 +
2 1 .7
= 28,392 N = 3.2 tons

Prof. J.S. Colton
55
Example 1.8
Power (kW )
F L VR
= T =
roller
2R
3
28,392 6.7 10 0.8

Power (kW ) / roll =
2 0.075
= 1.01 kW / roll = 1.35 hp
Prof. J.S. Colton
56
Example 1.9
Entrance
p=
'
Y flow
xb
xf
Exit
p=
'
Y flow
h
exp( (H b H ))
hb
h
exp( (H ))
hf

Prof. J.S. Colton
57
Example 1.10
(h h f )
R
R
R
tan 1
H =2
hf
hf

Prof. J.S. Colton
58
Example 1.11
Friction hill
pressure / 2Tflow
1.35
1.3
1.25
Exit
Entrance
1.2
1.15
1.1
1.05
1
0.95
0.9
0.00
0.20
0.40
0.60
0.80
1.00
/ max

Prof. J.S. Colton
59
Rolling
Normal Stress
Shear stress

Prof. J.S. Colton
60

Prof. J.S. Colton
61
Widening of material
Side view
Top view

Prof. J.S. Colton
62
Residual stresses due to frictional constraints

a) small rolls or small reduction (ignore friction)
b) large rolls or large reduction (include friction)

Prof. J.S. Colton
63
Defects
a) wavy edges
barreling
roll deflection
b) zipper cracks
low ductility
c) edge cracks
d) alligatoring
piping, inhomogeniety

Prof. J.S. Colton
64
Roll deflection
Rolls can deflect under load
Rolls can be crowned

Prof. J.S. Colton
65
Roll deflection
Rolls can be stacked for stiffness

Prof. J.S. Colton
66
Method to reduce roll deflection

Prof. J.S. Colton
67
Summary
Process
Equipment
Products
Mechanical Analysis
Defects

Prof. J.S. Colton
68

Prof. J.S. Colton
69

Rolling

Încărcat de

Informații document

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Rolling

Încărcat de

Drepturi de autor:

Formate disponibile

Deformation Processing Rolling

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

Model flat sheet

Plane strain analysis

( x + d x ) (h + dh ) 2 pR d sin 2pR d cos = 0

ME 6222: Manufacturing Processes and Systems

p x = 1.15 Y flow Y flow

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

Substituting and integrating

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

Effect of back and front tension

Average rolling pressure per unit width

ME 6222: Manufacturing Processes and Systems

Average rolling pressure - entry

Taylors series expansion

ME 6222: Manufacturing Processes and Systems

Average rolling pressure - entry

Average rolling pressure - exit

Taylors series expansion

ME 6222: Manufacturing Processes and Systems

Average rolling pressure - exit

ME 6222: Manufacturing Processes and Systems

again, very difficult to do.

ME 6222: Manufacturing Processes and Systems

Approximation based on forging

ME 6222: Manufacturing Processes and Systems

Small rolls or small reductions

pave = 1.15 Y flow

Large rolls or large reductions

ME 6222: Manufacturing Processes and Systems

Force approximation: low friction

= 1.15 LwY flow

ME 6222: Manufacturing Processes and Systems

Force approximation: high friction

= 1.15 LwY flow 1 +

ME 6222: Manufacturing Processes and Systems

Zero slip (neutral) point

Exit: material is pulled back into nip

ME 6222: Manufacturing Processes and Systems

Hence, the zero point must be where

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

Torque / roller = r Froller

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

Hence, maximum draft

2 flow = 1.15 Y flow