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 the product with different cross sections.

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1. Objectives of mechanics analysis

a. Physical phenomenon
b. Torque c. Power

d. Productivity/Velocity

System parameters

Operating parameters
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2. Physical phenomenon Spreading: mass conservation

w

t 0 w0 v 0 t f w f v f
Volume before rolling = the volume after rolling

v0 v f
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t 0 w0 L0 t f w f L f

Vo < Vr < Vf Friction causes the velocity of work piece to increase its velocity Inertia causes the velocity of work piece to decrease its velocity

No-slip point

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It is the friction between the work and the roll that drives the workflow between two rolls. The friction force is developed based on coefficient of the friction and roll force due to the contact curve.

The pressure varies along the contact length

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3. Condition to roll

draft, d = |tf-t0|: dmax

d m ax R
2
Friction coefficient
Radius of the roll

The (actual) draft should be less than d max

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4. Contact length

L R(t 0 t f )

5. Contact force

F w pdL
0

F Y f wL
N: rotation speed of the roll, rev / min
7

6. Torque
7. Power

T 0.5FL

P 2NFL
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For the rolling process, the true strain is:

t0 ln tf
The average flow stress is the same expression, i.e.

Yf

( Y f d )
0

k 1 n
n
8

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Example 1 (21.2): A 2.0-in. thick slab is 10.0 in. wide and 12.0 ft long. Thickness is to be reduced in three steps in a hot rolling operation. Each step will reduce the slab to 75% of its previous thickness. It is expected that for this metal reduction of the slab will widen by 3% in each step. If the entry speed of the slab in the first step is 40 ft/min, and roll speed is the same for the three steps, determine (a)

length and (b) exit velocity of the slab after the final
reduction
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Solution for example 1 (given in the classroom) Diketahui : Tebal = 2 in 75% = 0,5 in

Lebar = 10 in + 3% x 3 step
Panjang = 12 ft

Ditanya : a) Lf = ?
b) Vf = ?

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10

Example 2: 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.

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Solution for example 2 Lebar 10, tebal 1 (given in the classroom)

Diketahui : Lebar =10 in

Tebal = 1 in

Rroll = 20 in
Vo = 50 ft/min Miu = 35.000 lb/in2 E = 0.2 Ditanya : a) F=? b) T=? c) P=?
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