Deformation Processing -

Rolling

ver. 1

Prof. Ramesh Singh, Notes by Dr. 1

Singh/ Dr. Colton
 Overview
• Process
• Equipment
• Products
• Mechanical Analysis
• Defects

Prof. Ramesh Singh, Notes by Dr. 2

Singh/ Dr. Colton
 Process

Prof. Ramesh Singh, Notes by Dr. 3

Singh/ Dr. Colton
 Process

Prof. Ramesh Singh, Notes by Dr. 4

Singh/ Dr. Colton
 Process

Prof. Ramesh Singh, Notes by Dr. 5

Singh/ Dr. Colton
Ring Rolling

Prof. Ramesh Singh, Notes by Dr. 6

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Equipment

Prof. Ramesh Singh, Notes by Dr. 7

Singh/ Dr. Colton
Equipment

Prof. Ramesh Singh, Notes by Dr. 8

Singh/ Dr. Colton
 Products

Prof. Ramesh Singh, Notes by Dr. 9

Singh/ Dr. Colton
 Products
• Shapes
– I-beams, railroad tracks
• Sections
– door frames, gutters
• Flat plates
• Rings
• Screws

Prof. Ramesh Singh, Notes by Dr. 10

Singh/ Dr. Colton
 Products
• A greater volume of metal is rolled
than processed by any other
means.

Prof. Ramesh Singh, Notes by Dr. 11

Singh/ Dr. Colton
 Rolling Analysis
• Objectives

– Find distribution of roll pressure

– Calculate roll separation force (“rolling
force”) and torque
– Processing Limits
– Calculate rolling power

Prof. Ramesh Singh, Notes by Dr. 12

Singh/ Dr. Colton
 Flat Rolling Analysis
• Consider rolling of a flat plate in a 2-high
rolling mill

θ
V0 Vf (> V0)
hb hf

Width of plate w is large Æ plane strain

Prof. Ramesh Singh, Notes by Dr. 13

Singh/ Dr. Colton
 Flat Rolling Analysis

α
V0 N Vf (> V0)

hb Entry Zone Exit Zone hf

• Friction plays a critical role in enabling rolling Æ µ ≥ tan α

cannot roll without friction; for rolling to occur
• Reversal of frictional forces at neutral plane (NN)

Prof. Ramesh Singh, Notes by Dr. 14

Singh/ Dr. Colton
 Flat Rolling Analysis
Stresses on Slab in Entry Zone
p
µp

φ σx + dσx σx
N
µp
hb hf
p
N
Stresses on Slab in Exit Zone
dx
p
µp

σx + dσx σx

µp
p
Prof. Ramesh Singh, Notes by Dr. 15
Singh/ Dr. Colton
 Equilibrium
• Appling equilibrium in x (top entry, bottom exit)
(σ x + dσ x ) ⋅ (h + dh ) − 2 pR ⋅ dφ ⋅ sin φ ± 2µpR ⋅ dφ ⋅ cos φ − σ x h = 0

Simplifying and ignoring HOTs

d (σ x h )
= 2 pR ⋅ (sin φ m µ cos φ )
dφ

Prof. Ramesh Singh, Notes by Dr. 16

Singh/ Dr. Colton
 Simplifying
• Since α << 1, then sinφ = φ, cosφ = 1

d (σ x h )
= 2 pR ⋅ (φ m µ )
dφ

• Plane strain, von Mises

p − σ x = 1.15 ⋅ Y flow ≡ Y flow

′

Prof. Ramesh Singh, Notes by Dr. 17

Singh/ Dr. Colton
 Differentiating
• Substituting
[( ′ ⋅h
d p − Yflow ) ] = 2 pR⋅ (φ m µ )
dφ
• or

d   p  
′ ⋅
Y flow − 1 ⋅ h  = 2 pR ⋅ (φ m µ )
dφ   Y flow
′  
   

Prof. Ramesh Singh, Notes by Dr. 18

Singh/ Dr. Colton
 Differentiating

d  p   p  d
′ ⋅h⋅
Y flow
dφ  Y flow
+
′   Y flow
′
− 1 ⋅
 dφ
Y flow (
′ ⋅ h = 2 pR ⋅ (φ m µ ))
  

Rearranging, the variation Y’flow.h with respect to φ is small compared to

the variation p/ Y’flow with respect to φ so the second term is ignored

d  p 
′ 
dφ  Y flow  2R
p
= (φ m µ )
h
′
Y flow
Prof. Ramesh Singh, Notes by Dr. 19
Singh/ Dr. Colton
 Thickness
R
φ R
h = h f + 2 R ⋅ (1 − cos φ ) hb − h f
hb L 2
from the definition hf
of a circular segment 2
2
or, after using a Taylor’s series expansion, for small φ
φ2 φ4
cos φ = 1 − + L
2! 4!
2 0
h = h f + R ⋅φ
Prof. Ramesh Singh, Notes by Dr. 20
Singh/ Dr. Colton
 Substituting and integrating
 p 
d 
′ 
 Y flow 2R
∫ ∫h
 = (φ m µ ) ⋅dφ
p 2
2 R Hφ − µL
f + R ⋅φ
′
Y flow In[1]:= ‡ φ
hf + R φ2

µ ArcTanB F
LogAhf + R φ2 E
R φ
hf
Out[1]= 2R − +
hf R 2R

p h R  R 
ln = ln m 2 µ tan −1 φ  + ln C
Y f′ R hf  hf 
 

Prof. Ramesh Singh, Notes by Dr. 21

Singh/ Dr. Colton
 Eliminating ln()

h
′ ⋅ exp(m µH )
p = C ⋅ Y flow
R

R  R 
−1 
H =2 tan φ
hf  hf 
 

Prof. Ramesh Singh, Notes by Dr. 22

Singh/ Dr. Colton
 Entry region
• at φ = α, H = Hb ,
h
′ ⋅ exp(− µH )
p = C ⋅ Y flow
R
R
C = exp(µH b ) ′
p = Y flow
h
exp(µ [H b − H ])
hb hb

p = (Y flow
′ − σ xb ) exp(µ [H b − H ])
h With back tension=(Y’flow – σxb)
hb

R  R  R  R 
−1  −1
Hb = 2 tan α H =2 tan φ
 hf 
hf  hf  hf
 
 

Prof. Ramesh Singh, Notes by Dr. 23

Singh/ Dr. Colton
 Exit region
at φ = 0, H = Hf =0,

R p = (Y flow
′ )
h
exp(µH )
C= hf
hf
p = (Y flow
′ − σ xf ) exp(µH )
h With forward tension
hf

R  R 
−1 
H =2 tan φ
hf  hf 
 

Prof. Ramesh Singh, Notes by Dr. 24

Singh/ Dr. Colton
Effect of back and front tension
maximum pressure
pressure

Y
Y
Y − σ xb Y − σ xf

distance

Prof. Ramesh Singh, Notes by Dr. 25

Singh/ Dr. Colton
 Flat Rolling Analysis Results –
without front and back tension
Stresses on Slab in Entry Zone Stresses on Slab in Exit Zone
p p
µp
µp
σx + dσx σx σx
σx + dσx
µp
µp
p p
Using slab analysis we can derive roll pressure distributions for the entry
and exit zones as: h0 and hb are the same thing

2 h µ H −H 2 h µH
p= Yf e ( 0 ) R  R  p= Yf e
3 h0 H =2 −1
tan  φ 3 hf
hf  
 hf 
H0 = H @φ = α Exit Zone
Entry Zone
Prof. Ramesh Singh, Notes by Dr. 26
Singh/ Dr. Colton
Average rolling pressure – per unit
width
φ φn
1 n
1
pave,entry =− ∫
R(α − φn ) α
pentry Rdφ ; pave,exit =
Rφn ∫p
0
exit Rdφ

Prof. Ramesh Singh, Notes by Dr. 27

Singh/ Dr. Colton
 Rolling force
• F = pave,entry x Areaentry + pave,exit x Areaexit

Prof. Ramesh Singh, Notes by Dr. 28

Singh/ Dr. Colton
 Force
• An alternative method

α φn
F=
∫φ ∫
w ⋅ pentry ⋅ R ⋅ dφ + w ⋅ pexit ⋅ R ⋅ dφ
0
n

• again, very difficult to do.

Prof. Ramesh Singh, Notes by Dr. 29

Singh/ Dr. Colton
 Force - approximation
F / roller = L w pave

L ≈ R∆h
∆h = hb - hf

 have 
pave = f 
 L 

Prof. Ramesh Singh, Notes by Dr. 30

Singh/ Dr. Colton
 Derivation of “L”
R
circular segment φ R

h = h f + 2 R ⋅ (1 − cos φ ) L
hb − h f
hb 2
2 hf
Taylor’s expansion 0
2 4 2
φ φ
cos φ = 1 − + L
2! 4!
2
h = h f + R ⋅φ

R ⋅φ = L
Prof. Ramesh Singh, Notes by Dr. 31
Singh/ Dr. Colton
 Derivation of “L”
setting h = hb at φ = α, substituting, and rearranging

2
L
hb − h f = ∆h = R ⋅  
R
or

L = R ⋅ ∆h

Prof. Ramesh Singh, Notes by Dr. 32

Singh/ Dr. Colton
Approximation based on forging
plane strain – von Mises

 µL 
pave = 1.15 ⋅ Y flow 1 + 
 2have 

average flow stress:

due to shape of element

Prof. Ramesh Singh, Notes by Dr. 33

Singh/ Dr. Colton
 Small rolls or small reductions
have
∆= >> 1
L
• friction is not significant (µ -> 0)

 µL 
pave = 1.15 ⋅ Y flow 1 + 
 2have 
0
pave = 1.15 ⋅ Y flow

Prof. Ramesh Singh, Notes by Dr. 34

Singh/ Dr. Colton
 Large rolls or large reductions
have
∆≡ << 1
L
• Friction is significant (forging
approximation)

 µL 
pave = 1.15 ⋅ Y flow 1 + 
 2have 

Prof. Ramesh Singh, Notes by Dr. 35

Singh/ Dr. Colton
Force approximation: low
friction
have
∆≡ >> 1
L

F = 1.15 ⋅ LwY flow

roller

Prof. Ramesh Singh, Notes by Dr. 36

Singh/ Dr. Colton
Force approximation: high
friction
have
∆≡ << 1
L

F  µL 
= 1.15 ⋅ LwY flow 1 + 
roller
 2have 

Prof. Ramesh Singh, Notes by Dr. 37

Singh/ Dr. Colton
 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 vR
vR
material
material pull-back
pull-in

Prof. Ramesh Singh, Notes by Dr. 38

Singh/ Dr. Colton
 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(µH b )
= = exp(µ (H b − 2 H n ))
hf exp(2 µH n )

Prof. Ramesh Singh, Notes by Dr. 39

Singh/ Dr. Colton
 Neutral point

1  1 hb 

Hn = H b − ln
2  µ hf 


hf H h f 
φn = tan  n
R  2 R 
 

Prof. Ramesh Singh, Notes by Dr. 40

Singh/ Dr. Colton
 Torque
paveA
L ≈ R∆h
L/2
R
∆h = hb - hf Froller
α φn
∑F =0
∫φ wµpR 2 dφ −
∫ wµpR 2 dφ
y
T=
∴ Froller = pave A
n entry 0 exit

L Froller L
Torque / roller = r ⋅ Froller = ⋅ Froller =
2 2
Prof. Ramesh Singh, Notes by Dr. 41
Singh/ Dr. Colton
 Power
Power / roller = Tω = FrollerLω / 2

ω = 2πN
N = [rev/min]

Prof. Ramesh Singh, Notes by Dr. 42

Singh/ Dr. Colton
 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).

Ff cosα ≥ Fn sin α
R ∆h/2
α F f = µ ⋅ Fn
α α
tan α = µ
Ff Fn
µ = friction coefficient
Prof. Ramesh Singh, Notes by Dr. 43
Singh/ Dr. Colton
 Processing limits
Also
∆h
R−
cos α = 2 = 1 − ∆h
R 2R
and
∆h << R sin α = 1 − cos2 α

0
2
∆h  ∆h  ∆h
sin α = 1 − 1 + −  sin α ≈
2R  2R  R

∆h
R ∆h ∆h
tan α = ≅ ≈
∆h  ∆h 
2
R − ∆h R
1− + 
R  2R 

Prof. Ramesh Singh, Notes by Dr. 44

Singh/ Dr. Colton
 Processing limits
So, approximately
∆h
(tan α )
2
=µ =
2

Hence, maximum draft

∆hmax = µ 2 R

Maximum angle of acceptance

φmax = α = tan −1 µ

Prof. Ramesh Singh, Notes by Dr. 45

Singh/ Dr. Colton
 Processing Limits
R

h0 hf

Max. reduction in thickness

( ∆h )max = µ 2 R
Max. angle of acceptance

φmax = α = tan −1 µ
Prof. Ramesh Singh, Notes by Dr. 46
Singh/ Dr. Colton
 Cold rolling
(below recrystallization point)
strain hardening, plane strain – von
Mises
Kε n
2τ flow = 1.15 ⋅ Y flow = 1.15 ⋅
n +1

average flow stress:

due to shape of element

Prof. Ramesh Singh, Notes by Dr. 47

Singh/ Dr. Colton
 Hot rolling –
(above recrystallization point)
strain rate effect, plane strain - von
Mises
• Average strain rate

V ε  h 
ε = = ln
& R  b 
t L  hf 

2τ flow = 1.15 ⋅ Y flow = 1.15 ⋅ C ⋅ ε
& m

average flow stress:

due to shape of element
Prof. Ramesh Singh, Notes by Dr. 48
Singh/ Dr. Colton
 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. Ramesh Singh, Notes by Dr. 49

Singh/ Dr. Colton
 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 (µ = 0.1)
• K = 720 MPa, n = 0.46

Prof. Ramesh Singh, Notes by Dr. 50

Singh/ Dr. Colton
 Example 1.3
• Maximum draft:
∆hmax = µ2R
= (0.1)2 • 75 = 0.75 mm
∆hactual = hb - hf = 2 - 1.4
= 0.6 mm

Prof. Ramesh Singh, Notes by Dr. 51

Singh/ Dr. Colton
 Example 1.4
• Maximum angle of acceptance

φmax = tan-1 µ = tan-1(0.1) = 0.1 radian

α=
(hb − h f ) = (2 − 1.4)
R 75
= 0.089 rad = 5.12o

Prof. Ramesh Singh, Notes by Dr. 52

Singh/ Dr. Colton
 Example 1.5
• Roller force: F = L w pave
• L = (R∆h)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  µL 
F = 1.15 ⋅ LwY flow 1 + 
roller
 2have 

Prof. Ramesh Singh, Notes by Dr. 53

Singh/ Dr. Colton
 Example 1.6

 hf 
 = ln
1.4 
ε f = ln   = 0.36
 hb   2 

Kε nf
2τ flow = 1.15 ⋅ Y = 1.15 ⋅
n +1
720 ⋅ (0.36)
0.46
= 1.15 ⋅ = 354 MPa
1.46

Prof. Ramesh Singh, Notes by Dr. 54

Singh/ Dr. Colton
 Example 1.7

F  µL 
= 1.15 ⋅ LwY flow 1 + 
roller
 2have 
−3 −3
= 6.7 × 10 ⋅10 × 10 ⋅ 354 × 10 6

 0 .1 × 6 .7 
× 1 + 
 2 × 1 .7 
= 28,392 N = 3.2 tons

Prof. Ramesh Singh, Notes by Dr. 55

Singh/ Dr. Colton
 Example 1.8

Power (kW ) = T ×ω =
F ⋅ L ⋅ VR
roller 2⋅R

−3
28,392 ⋅ 6.7 × 10 ⋅ 0.8
Power (kW ) / roll =
2 ⋅ 0.075
= 1.01 kW / roll = 1.35 hp

Prof. Ramesh Singh, Notes by Dr. 56

Singh/ Dr. Colton
 Example 1.9
• Entrance

p= ( '
Y flow − σ xb ) h
hb
exp(µ (H b − H ))

• Exit

p= ( '
Y flow − σ xf ) h
hf
exp(µ (H ))

Prof. Ramesh Singh, Notes by Dr. 57

Singh/ Dr. Colton
 Example 1.10

φ=
(h − h f )
R

R  R 
H =2 tan −1 φ 
hf  hf 
 

Prof. Ramesh Singh, Notes by Dr. 58

Singh/ Dr. Colton
 Example 1.11
Friction hill
1.35
1.3
1.25 Exit Entrance
pressure / 2Tflow

1.2
φ
1.15
1.1
1.05
1
0.95
0.9
0.00 0.20 0.40 0.60 0.80 1.00
φ / φ max

Prof. Ramesh Singh, Notes by Dr. 59

Singh/ Dr. Colton
 Rolling

Normal Stress

Shear stress

Prof. Ramesh Singh, Notes by Dr. 60

Singh/ Dr. Colton
Prof. Ramesh Singh, Notes by Dr. 61
Singh/ Dr. Colton
Widening of material
φ

Side view

Top view

Prof. Ramesh Singh, Notes by Dr. 62

Singh/ Dr. Colton
 Residual stresses -
due to frictional constraints
a) small rolls or small reduction (ignore friction)
b) large rolls or large reduction (include friction)

Prof. Ramesh Singh, Notes by Dr. 63

Singh/ Dr. Colton
 Defects
• a) wavy edges • c) edge cracks
– roll deflection – barreling

• b) zipper cracks • d) alligatoring

– low ductility – piping, inhomogeniety

Prof. Ramesh Singh, Notes by Dr. 64

Singh/ Dr. Colton
 Roll deflection
Rolls can deflect under load

Rolls can be crowned

Prof. Ramesh Singh, Notes by Dr. 65

Singh/ Dr. Colton
 Roll deflection

Rolls can be stacked for stiffness

Prof. Ramesh Singh, Notes by Dr. 66

Singh/ Dr. Colton
Method to reduce roll deflection

Prof. Ramesh Singh, Notes by Dr. 67

Singh/ Dr. Colton
 Summary

• Process
• Equipment
• Products
• Mechanical Analysis
• Defects

Prof. Ramesh Singh, Notes by Dr. 68

Singh/ Dr. Colton
Prof. Ramesh Singh, Notes by Dr. 69
Singh/ Dr. Colton