Unit4(Class14)Rolling

DefectsinMetalWorkingProcess
DefectsintheFinalProductofMechanicallyworkedmetalmayhaveoriginatedfromanyoneora
combinationofthefollowing:TheingotusedforMWmaycontaindefects(pores,microcracksor
inclusions)whichmayremainassuchorgetaggravatedduringworkingoperation.

1 OperationalParametersLocalizedtoaparticulartypeofMWprocess(notfollowing
theproperpractice).
DefectsinRolledProducts
1) Generalb)Operational
1) General
Thedefectsmayarisedueto
i)Surfaceirregularities:Theingotortherawmaterialmaybehavingirregularitiesdueto
scalingwhichwillgettrappedinthemetalandremaininsidethemetalsurfaceaslaps.This
needstoberemovedbygrindingandtherewillbemetalloss.Ifthedefectisdeepandsevere
theproductmaygetrejected.
ii)Nonmetallicinclusions:Theinclusionsmayresultsfromoxidesornitridesorsilicatesetc.,
especiallyinsteels.Thesearepresentinthemoltenmetalduringthepreparation.Iflessin
volumemaycausesmallcracksinthemetalandifmoreinvolumewillresultinseverecracks
calledcrocodilecracksseparatingtheproductintotwohalves.
iii)InternalPores:Theremaybeporesintheproductduetothepresenceofgaseslike
hydrogen,oxygen,nitrogenetc.,Iftoomuchgasesarepresentleadstoelongationofthepores
andtheproductmaybecomeweaker.Sometimesseparationmaytakeplaceresultingincracks.
i)Barrel:Duetofrictionattheedgesoftheproductbarrelactiontakesplace.Surfaceincontact
experienceseverefrictionascomparedtocenterofthework.Hence,withheavyreductionin
theworkthecentertendstoexpandlaterallymorethantheoutersurfacesincontactwiththe
diesandproducesbarrelededges.

ii)Nonuniformdeformation:Whentherollingconditionsaresuchthatonlysurfaceofthe
workpieceisdeformed.Thecrosssectionoftheslabisdeformedintotheshapeasshown.
Themiddleportionislessdeformedascomparedtotheoutersurface.
Thismaybeduetovariationintemperatureinthemetal.Surfacetemperaturebeingmorethan
theinsidetemperatureoftheslab.
iii)AlligatorCracks:Ifthereisanymetallurgicalweaknessinthemetal(duetothepresence
ofinclusions)alongthecentrelineoftheslab,fracturewilloccur.Thisresultsintheseparation
ofthelayergivingrisetoopeningoftheslabwhichlookslikeanalligatormouthinopening
position.Hence,thename.
Others:
1)
Hydrogencracks:Duringpreparationofthemeltinthefurnaceseveralgasestriestoget
intothemelt.OutofthisHydrogengasdiffusesintothemelttoalargeextentandisretainedin
thesolidmetal.Duethepresenceofhydrogeninexcessinternalcracksappearthroughthecross
sectionduringrollingandcannotbeused.Itisamajorproblemwithalloysteelsespecially.
2)
Nonmetallicinclusion:Inclusionsarenonmetallicsappearinginthemetalasaresult
ofentrapment.Duringthepreparationofthemoltenmetalnonmetalliclikeoxides,nitrides,
silicatesenterthemeltandremainassuchinthesolidmetal.Thesearediscontinuitiesinthe
metalandreducethepropertiesofthemetal.Onrollingtheymayresultincrackswhichmay
reachacriticalvalueandmaketheproductrejectable.
Defects:Operational
1)

Waviness..Varyingthickness.

2)

EdgeCracking

i)Waviness..Varyingthickness.
Variationintheworkacrossthewidthinsheetrollingoccursbecausetherollgapisnotperfectly
parallel(a).
Sincewidthandvolumeareconstantandthicknessisvarying,theedgeselongatemorethanthe
center(b).
Butthesheetisacontinuousbody;thestrainsreadjusttomaintaincontinuity.

Thusthecenterportionisintensionandtheedgesareincompression(c).
Theresultisawavyedge(d).

ii)EdgeCracking
Thelengthofthecenterportionincreasesbuttheedgesarepreventedduetofrictionalforce.
Asaresultthematerialgetsroundedoff(a).
Theedgesarestrainedintensionleadingtoedgecrackingalongthewidthoftheslab(b).
Whenthedifferenceinthestrainsbecomeexcessi.e.underseverecondition,splitatthe
centeroftheslaboccurs(c).
Numericals
Prob,1.Determinethemax.possiblereductionforcoldrollinga300mmthickslabwhen
=0.08andtherolldiameteris600mm.
i) t)max=?forcoldrollingt=300mm
R=600/2=300mm
ii)forhotrollingt)max=?
iii)%reduction=?
i)Max.Possiblereduction
i)Coldrolling
2

Weknowt)max= .R

Substitutingthevaluesweget

=(0.08) .(300)
Max.Possiblereduction=1.92mm
35)

hotrolling
20)

2
max= .R
2

(0.5) .(300)

1=

Max.Possiblereduction=75mm
ii)%reduction
Coldrolling=(t/t).100
1= (1.92/300).100
2= 0.64%
Hotrolling=(75/300).100
=25%

Prob.2.Ifthemax.reductioninrollingofslabisfrom25to20mm,calculatethevalueof
coeff.friction.Taketherolldiameteras500mm.Alsofindthelengthofprojectionofarcof
contact.
Given:
t0=25mmt1=20mm2R=500mm=?Lp=?
R=250mm
Max.reduction
From

t=2520=5mm

Cos=(1t/2R)
=(15/500)
Cos=0.99
0

Angleofbite=8.11
Weknow=tan=tan(8.11)

Coeff.offriction=0.1425
LengthofProjectionofarcofcontactLp
Lp=(R.t)
=(250)(5)
Lp=35.35mm
Prob.3.Ifthecoeff.Offrictionincoldrollingis0.08,determinethei)lengthofprojectionof
arcofcontactii)thevelocityoftheslabattheexit
iii)specificrollpressure.Neglectlateralspread.Usethefollowingdata.
Widthoftheslab=b=80mm,Rollradius=800mmthicknessoftheslab=to=400mm,velocity
oftheslabattheentry=Vo=200mm/sec,Rollingload=P=14MN.

from

t)max= .R
2

=(0.08) .(800)=5.12mm
i)Lp=(R.tmax)=(800)(5.12)=64mm
weneedtocalculate
thicknessoftheslabafterrolling
tmax=(totf)
5.12=400tf
tf=4005.12=394.88mm
ii)Specificrollpressureisgivenby
p=(P/b.Lp)
6

1= (14x10 /800.64)=273.44N/mm2
1= 273.44Mpa
iii)Thevelocityoftheslabattheexit
weknowforconstantvolumeofthemetalinrollingassumingconstantwidth
bV0t0=bVftf
200(400)=Vf(394.88)

Vf=202.593mm
Prob.4.Aluminiumstripof400mmwideand25mmthickisrolledusinga1800mmdia.Rollat
250rpm.Thethicknessisreducedto20mm.Ifis0.5forhotrollingand0.45forcoldrolling,
calculatethetorqueandpowerrequiredtorollthemetal.Takethespecificrollpressure
250Mpaforhotrollingand300Mpaforcoldrolling.
Given:b=400mm,R=D/2=1800/2=900mm
to=25mm,tf=20mm,p=250Mpa(hotrolling)andp=300Mpa(forcoldrolling)
N=250rpm=(250/60),=0.5forhotrolling
=0.45forcoldrolling
TorqueMt=?Power=?
a=distancefromthecenteroftherollwheretotalrollingloadisassumedtobeconcentrated.
Weknow
=(a/Lp)=(a/R.t)
=a/900(2520)=a/(67.08)
Forhotrollingsubstitute=0.5
0.5=a/67.08
therefore

a=33.54mm

againp=(P/b.Lp)
250=P/(400.33.54)
Rollingload=67080000Nor6.708MN
TorqueMt=2P.a
1=
1=

2(6.708)(33.54)/1000
0.45MNm

Workdone=2(2..a).P=4P.a
1= 4(33.45)6.708/1000
2= 2.83MNm
Power=Workdone/sec=(4P..a)N/60
=(2.83x250)/60

=11.79MW
Forcoldrolling=a/(67.08)
0.45=a/67.08
a=30.186mmor0.030m
againfromp=(P/b.Lp)
300=P/(400x67.08)
P=8049600N=8.05MN
TorqueMt=2P.a
=2x8.05x0.03=0.483
MNmWorkdone=4P.a=4(8.05)(0.03)
=3.035MNm
Powerrequired=(4P..a)N/60
1= 3.035x250/60
2= 12.648MW
EquationsusedinRollingProcess
2

i)

Maximumdraftt)max= R,=tanandt)max=to

tf
2)

Cos=1t/2R

iii)LengthofarcofcontactLp=R.t
iv)SpecificRollPressurep=P/b.Lp
v)ConstantVolumeRate,bVoto=bV1t1=constant
vi)TorqueMt=2Pa=a/Lp
=0.50hotrolling
=0.45coldrolling

vii)Powerrequired=(2.2a.P)N/60
=(4a.P)
(N/60)

viii)Forwardslip=(V1Vn)/V1
x)Backwardslip=(VnV0)/V0
xi)Volumerateofdeformationisthe
ratio of volume of the work to
thetimefordeformation
={b(tot1)Lp}/T