Int J Adv Manuf Technol
DOI 10.1007/s00170-016-8890-z
ORIGINAL ARTICLE
A simplified method to calculate the rolling force in hot rolling
Si Li 1 & Zhigang Wang 1 & Changming Liu 1 & Jinhua Ruan 1 & Zengbing Xu 1
Received: 15 December 2015 / Accepted: 9 May 2016
# Springer-Verlag London 2016
Abstract It is well known that there are sharp peaks (friction
hills) in the specific roll pressure curves predicted by Sims
formula and eo formula which result in large errors
for hot rolling. In this paper, a new specific roll pressure for-
mula is derived from the Navier-Stokes equation (N-S
equation) by the hydrodynamics method (HM) with assump-
tions that strip materials take the characteristics of viscous
fluid during plastic deformation of hot rolling processes.
Results predicted by this HM formula, Sims formula, and
eo formula were compared with experimental data. It
was found the friction hills in the specific roll pressure curves
predicted by Sims formula and eo formula are
smoothed by this newly established formula and higher accu-
racy can be achieved in the calculation of the unit width
rolling force.
Keywords Hydrodynamics method (HM) . Hot rolling . The
specific roll pressure . Friction hill . Rolling force
1 Introduction
Calculation of rolling pressure is an important subject in strip
hot rolling processes. It is not only a necessary information in
strength check and stiffness design of all sorts of equipment
parts, but also an important theory basis for the determination
of the process system. In the hot rolling process, accurate
* Zhigang Wang
wzhigang@wust.edu.cn
1
The Key Laboratory of Metallurgical Equipment and Control of
Education Ministry, Wuhan University of Science and Technology,
Wuhan 430081, China
rolling pressure is of great significance for production of
high-quality and high-precision strip which can be calculated
by integration of the specific roll pressure along contact arc.
Many theories and methods for calculating the specific roll
pressure have been proposed [114]. We have the cross sec-
tion method [14], the slip line method [57], the upper bound
method [810], and the finite element method [1114]. It is
well known that the Karman-eo equation [1] and
Orowan-Sims equation [2, 3] usually applied in hot rolling
are the cross section method, which have large errors in the
calculation results due to the sharp peak (friction hill) in the
specific roll pressure curves, and cannot determine the stress-
strain field in the deformation zone. The slip line method
[57] can obtain the stress state and the metal flow trend of
metal deformation in plane deformation due to rigorous and
complete mathematical theory. But, this method can only deal
with the plane problems and the axisymmetric problems.
Moreover, structuring the slip line fields is tedious and incon-
venient in the deformation zone. The upper bound method
[810] can maturely solve force-energy problems in rolling
processes and it can also predict the temperature distribution
in the rolling process. However, it is normally used for rigid-
plastic material with constant flow stress, and distribution of
the specific roll pressure cannot be predicted by this method.
With high-speed development of large computers, the finite
element method is widely used in solving the rolling forming
problem. The finite element method [1114] can obtain an
accurate calculation result based on the rigorous theory, but
the fine element division will lead to a complex solution pro-
cess and massive computational time. Moreover, by merely
partially meeting real boundary conditions limited its possibil-
ity for practical production.
In the rolling process, experimental data was used to verify
accuracy of the specific roll pressure formula. In this context,
researchers have made a lot of efforts to accurately measure
 Int J Adv Manuf Technol

distribution of the specific roll pressure in the deformation

zone. For example, Hum et al. [15] measured the distribution
of specific roll pressure in hot rolling of aluminum 1100 and
Daniel et al. [16, 17] used the optical fiber sensor to measure
the distribution of specific roll pressure by inverse analysis
during strip rolling. Up to now, due to the lack of an accurate
and simple prediction model for the specific roll pressure, the
theoretical prediction could not match the experimental results
satisfactorily.
Existing methods usually ignore material velocity
which results in inaccurate prediction of the specific roll Symmetry
pressure. In the rolling process, researchers have found line
that the roll speed in the deformation zone has a signifi- Rolling direction

cant influence on the specific roll pressure. Wang et al.
[18] found that the friction coefficient decreases with in-
creasing oil film thickness due to the increase in rolling
speed, which leads to fluctuation of the rolling pressure.
Le et al. [19] confirmed that the rolling force decreased
with increasing rolling speed due to the decrease in fric-
tion coefficient.
In a hot rolling process, materials plastic deformation in
the deformation zone shares similar properties with viscous
fluid [20]. This paper attempts to use the fluid mechanics
theory to describe the deformation and stress of material in
the plastic deformation zone. Considering the influence of
relative sliding velocity, the specific roll pressure formula
was derived from the Navier-Stokes equation (N-S equation).
Through comparison of experimental results with theoretical
predictions by the proposed hydrodynamics method (HM),
Sims formula, and eo formula for hot rolling, it was
found that the HM method leads a better solution to smooth
the friction hill, and the errors of rolling force predicted by
HM method are smaller than those predicted by both Sims
formula and eo formula.
2 Hydrodynamics method
Fig. 1 The distribution of velocity in deformation zone
exit plane are not the deformation region boundaries where the
velocity distribution changes from homogeneous to inhomo-
geneous, which is already beyond the entry plane and ahead
the exit plane.
The volume constancy hypothesis in rolling process can be
written as
W V 1 h1 W V xm 2hx W V 0 h0 1
where W is the strip width, h0 and h1 are strip thicknesses at the
entry plane and the exit plane, hx is a half of the strip thickness
in the deformation zone corresponding to x-coordinate, and
V0, Vxm, and V1 are the mean velocities in the x direction
corresponding to h0, hx, and h1. The material mean velocity
in the x direction at height hx can be obtained by
h1 V 1 h0 V 0
V xm 2
2hx 2hx
Using the definition of forward slip Sf = (V1 VR)/VR, the
velocity at the exit plane V1 can be written as


V1 VR 1 Sf 3

In order to derive the specific roll pressure formula, Navier- where VR is the rollers surface velocity.
Stokes (N-S) equation should be simplified to determine the By the geometry in deformation zone, the contact length
material velocity. It assumes that the material is incompress- can be expressed as
ible and is treated as the small Reynolds number flow in the r
.
deformation zone. In a hot strip rolling process, plane strain L Rhh2 4 4
assumption is made in the deformation zone due to the strip
having a large width/thickness ratio.
where R is the roller radius and h = h0 h1 is the absolute
thickness reduction. It should be pointed out that the elastic
2.1 Material velocity
flattening of the roller is neglected in this hot rolling process.
For a given rolling process, the interface curve between the
As shown in Fig. 1, a half of the strip was taken into consid-
roller and the strip can be expressed as
eration due to its symmetry about the x-axis in rolling process.
The friction-caused shear stress leads to inhomogeneous dis-
tribution of the velocity across the thickness direction in the h 2 h1
hx x 5
deformation zone. It was noted that the entry plane and the 2L2 2
Int J Adv Manuf Technol

Differentiating Eq. (5) with respect to x leads to at the considered point (x,y) in the deforming region can be
given by
dhx h
2 x 6
dx L 1 dp
2 2 
Vx y hx V R 12
2 dx
Under the plane strain assumption, ignoring the inertial
force and the internal force, the N-S equation can be simplified Then, the mean velocity of the vertical section in the x
as direction at the considered point (x,y) in the deforming region
can be obtained by
p 2 V x
2 7 Z hx
x y 1
V xm V x dy
hx 0  
where is the dynamic viscosity, MPas, Vx is the velocity in Z hx
1 1 dp
2 2 
the x direction of the considered point (x, y) in the deformation y hx V R dy 13
hx 0 2 dx
zone corresponding to x-coordinate, and p is the specific roll 1 dp 2
pressure (or the pressure of any point in the deformation h V R
3 dx x
zone).
By assuming that the velocity component in the x direction Equation (13) can be rewritten as follows:
Vx is much bigger than that in the y direction Vy, that is,
p p dp 3
x >> y . Therefore, another assumption can be made 2 V R V xm 14
p p
dx hx
y 0, i.e.,
x
dp
dx .
Under the above assumption, Eq. (7) can be rewritten as Substituting Eq. (14) into Eq. (12) becomes

dp 2 V x 3

2 0 8 Vx 2
V R V xm y2 h2x V R 15
dx y 2hx

Integrating Eq. (8) with respect to y leads to Substituting Eq. (2) into Eq. (15), and considering the di-
rection of the mean velocity Vxm in the x direction, the velocity
1 dp 2 in the x direction at the considered point (x,y) in the deforming
Vx y C 1 xy C 2 x 9
2 dx region can be expressed as
!
Under the condition of symmetric rolling, the distribution 3 V R h1 V 1
2 2 
of Vx is symmetric about plane y = 0 and Vx is an even function Vx y hx V R 16
2 h2x 2h3x
of y, which leads to C1(x) = 0 in Eq. (9). Therefore, we can
rewrite Eq. (9) as
According to volume constancy of plane strain, the strain
1 dp 2 relationship can be established as follows:
Vx y C 2 x 10
2 dx V x V y
x ; x ; x y 0 17
The strip velocities in the hot rolling which present a x y
property of viscous fluid equals to the rollers surface
The material velocity in y direction can be obtained by
velocity at the interface between the strip and the roller,
substituting Eq. (16) into Eq. (17) and we have
namely Vx(x,hx) =VRcos. A minus sign in front of VR
due to the opposite direction of the roll horizontal veloc- " ! 
ity component is in contrast to the x-axis, is the contact 3 h 3h1 V 1 2V R y2 2
Vy xy 3 h
angle at the considered point (x,y) in the deforming re- 2 L2 2h4 hx 3 x
!# x 18
gion, and max = where is the bite angle. The bite V R h1 V 1
angle is very small in the strip rolling and is even 2hx
h2x 2h3x
smaller than , so it is reasonable to assume that
cos 1. Thus,
V x x; hx V R 11 Figure 2 illustrates the velocity distribution in the
deforming region. The abscissa is the non-dimensional con-
tact length with the scale of x/L while the ordinates are non-
Substituting Eq. (11) into Eq. (9) obtains dimensional velocities in the x direction in Fig. 2a and in the y
C 2 x 2 dx hx V R . Hence, the velocity in the x direction
1 dp 2
direction in Fig. 2b, respectively.
 Int J Adv Manuf Technol

Fig. 2 Various velocities in the 1.2 0.1

deformation zone. a Vx; b Vy y=0.5h 1

No n -d im en sio n al v elocity
No n -d im en sio n al v elo city
0.08 y=0.25h 1
1 N
y=0.125h 1
0.06
0.8
0.04
y=0
0.6 y=0.25h 1
0.02
y=0.5h 1

0.4 0
0 0.2 0.4 0.6 0.8 1 0 0.2 0.4 0.6 0.8 1
Non-dimensional contact length Non-dimensional contact length
(a) (b)

In Fig. 2a, the material velocity Vx gradually decreases from 2.2 The specific roll pressure
the symmetry plane y = 0 to the interface between the roller and
the strip in the forward slipping zone. The direction of the Equation (14) can be rewritten as
friction force acting on the interface of the strip is opposite to
dp dp dhx 3
the rolling direction in the forward slipping zone. The shear 2 V R V xm 19
stress caused by friction will resist the material flow which dx dhx dx hx
makes the surface velocity slower than the center velocity. As
By substituting Eq. (2), Eq. (5), and Eq. (6) into Eq. (18),
shown in Fig. 2a, the material velocity Vx gradually increases
the specific roll pressure is given by
from the symmetry plane to the interface between the roller and
r
.  r
the strip in the backward slipping zone. In this case, the friction p 3V 1 4R 2hx h1
p 3 2L L h p arctan
force has the same direction of the rolling direction. The shear 2h1 h1 h1 #
20
stress caused by the friction promotes the material flow which 3V xm 2hx h1 p 5V xm V R p
2hx h1 2hx h1 C 0
makes the surface velocity faster than the center velocity. 4hx h21 4hx h1 hx h21
Figure 2a also shows that the different velocity curves intersect
at the neutral point N. In the neutral plane, the friction stress is where C0 is the integral constant determined by boundary
zero, and the shear stress caused by friction is equal to zero. condition.
Therefore, materials all over the neutral plane have the same It was found that the specific roll pressure values calculated
velocity, which is consistent with predicted results obtained by by Eq. (20) have some differences from the experimental data
the proposed HM formula shown in Fig. 2a. after the coefficient of the dynamic viscosity, , is determined.
In Fig. 2b, the material velocity Vy decreases from the in- Due to the relative sliding between the roller and the strip, the
terface to the symmetric plane. The material velocity Vy is strip velocity in the x direction is not completely equal to the
equal to zero in the symmetry plane due to the symmetry rollers surface velocity in the x direction. The factor of relative
assumption. It can also be seen that Vy increases gradually velocity due to the specific roll pressure Kp is used to correct the
along the contact arc from the entry plane to the exit plane. material mean velocity Vxm, i.e., Vxm is replaced by KpVxm. In
this case, the calculated value of the dynamic viscosity coeffi-
In addition, it can be seen that Vx is greater than Vy from the
cient is different from the original value in Eq. (20). So, the
longitudinal axis value. The assumption (p p
y 0, x dx ) of
dp
coefficient of dynamic viscosity due to the specific roll pressure
rationality is further verified due to the fact that the pressure p is used to replace . The values of Kp and p have to be
gradient is proportional to the velocity. determined by experiments. Therefore, Eq. (20) becomes

Table 1 Experimental
parameters obtained by Hum et al. Rolling Initial Reduction Roll radius Roll speed Forward Flow stresses
[15] and Anand et al. [24] in hot temperature thickness (%) (mm) (rmp) slip (MPa)
rolling process (C) (mm)

504 6.32 30.40 125 80 0.03456 f = 10 + 90.06

487 6.30 39.21 125 100 0.04558 f = 15 + 9.20.11
Int J Adv Manuf Technol

Fig. 3 Comparisons of the

specific roll pressure between
experimental data obtained by
Hum [15] and results predicted by
the HM, Sims formula [3], and
eo formula [1] in hot
rolling. a The data in 504 C. b
The data in 487 C

r
.  r
p 3V 1 4R 2hx h1 which has been believed to have a significant influence on the
p 3 2p L L h p arctan
2h1 h1 h1 # specific roll pressure [2123]. The effect of the temperature is
21
3K p V xm 2hx h1 p 5K p V xm V R p directly involved from the material flow stress f, the coeffi-
2hx h1 2hx h1 C
4hx h21 4hx h1 hx h21 cient of dynamic viscosity due to the specific roll pressure p,
and the factor of relative velocity due to the specific roll pres-
Using the boundary condition p = f, and Vxm = V1 when sure Kp.
hx = h1 / 2, the integral constant C can be obtained by Ignoring the strip width spread, it can be considered
r that the normal stress in contact interface is approximate-
p . 5K p V 1 ly equal to p, so that the unit width rolling force can be
C 3 2p L L h f 22
2h21 obtained as follows:
where f is the flow stress. Z L
By substituting of Eq. (22) into Eq. (21), the specific roll P0 pdx 24
pressure is obtained as follows: 0

r
.  r
p 3V 1 4R 2hx h1
p 3 2p L L h p arctan
2h1 h1 h1 # 3 Results and discussions
3K p V xm 2hx h1 p 5K p V xm V R p 5K p V 1
2h x h 1 2h x h1 f
4hx h21 4hx h1 hx h21 2h21
To validate Eq. (23) of the specific roll pressure, it is necessary
23 to compare the predicted results by the HM method with ex-
It is worth noting that the specific roll pressure expressed in perimental data as well as with the predicted results by Sims
the Eq. (23) does not directly consider the strips temperature formula and eo formula. Experimental data were

Fig. 4 The influence of relative 180

factors on the specific pressure in
the HM method. a The factor of Kp=0.5
Sp ecific ro ll p r essu re , MPa

relative velocity due to the 135

specific pressure. b The factor of
relative viscosity due to the Kp=0.6
specific pressure 90

Kp=0.7
45

Kp=0.8
0
0 4.5 9 13.5 18
Contact length , mm Rolling direction

(a) (b)
 Int J Adv Manuf Technol

Table 2 Comparisons of the unit width rolling force between

experimental data obtained by Hum et al. [15] and theoretical results
predicted by the HM, Sims formula [3], and eo formula [1]

Reduction Experimental HM Sims eo

(%) data (N/mm) (N/mm) (N/mm) (N/mm)

30.4 1004 887 740 804

39.21 1457 1248 1100 1103

pressure increases with a roll speed because increasing defor-

mation rate results in an increasing deformation resistance.
The results of rolling force calculated by Eq. (24) are listed
in Table 2. It can be found that the results predicted by the HM
method are much closer to the experimental data than those
predicted by both the Sims formula and eo formula.
It should be noted that the errors of rolling force predicted
Fig. 5 The influence of roll speed on the specific roll pressure
by HM method are smaller than those predicted by both Sims
formula and eo formula, but it is still large (more than
chosen from [15, 24] and the experimental parameters are 10 %). The flow stress of aluminum alloy 1100-H14 used in
shown in Table 1. The material used in the experiment is this investigation is just taking the strain into account.
aluminum alloy 1100-H14. Actually, strain rate also influences the flow stress [25, 26].
When the HM method was used, first, experimental data Further investigation is needed to improve the accuracy of the
for a given process were plotted out. Secondly, the values for rolling force prediction for online control.
both factors due to the specific roll pressure, Kp and p, in
Eq. (23) were chosen to determine the specific roll pressure
to fit with the experimental data.
4 Conclusions
In this paper, the predicted curves adopting the resistance to
plane deformation (K) values could not fit the experimental
1. Because the material plastic flow in the deforming region
data in the Sims formula. Therefore, the value of the resistance
has the properties of viscous fluid in hot rolling, the spe-
to plane deformation (K) is chosen as an approximate double
cific roll pressure formula was derived by the hydrody-
of the flow stress (f) for a given rolling process. To fit the
namics method. Comparing with the theoretical curves
experimental data, values of 0.27 and 0.22 are chosen for
predicted by the HM method, Sims formula, and
reductions of 39.21 and 30.4 % in the eo formula,
eo formula, it was found that the HM method leads
respectively.
a better solution to smooth the friction hill.
Figure 3 shows that the curves predicted results by the HM
2. Not only the roll radius, the strip thickness, and the flow
agree with the experimental data better than those by the Sims
stress but also the roll speed affected the specific roll pres-
formula and eo formula. The curves predicted by the
sure. All these parameters are considered in the HM meth-
Sims formula and eo formula have sharp peaks (friction
od. Reasonably, choosing the factor of relative velocity
hills) while application of the HM method has smoothed the
due to the specific roll pressure Kp and the factor of rela-
friction hill.
tive viscosity due to the specific roll pressure p can prop-
Figure 4 illustrates the influences of the factor of relative
erly predict the specific roll pressure.
velocity due to the specific roll pressure Kp and the coefficient
3. The HM method only needs one equation to predict the
of dynamic viscosity due to the specific roll pressure p on the
specific roll pressure while the other methods need two
specific roll pressure. In Fig. 4a, the amplitude of the specific
different equations: one for the backward slip zone and
roll pressure decreases with increasing Kp, as well as the lo-
the other for the forward slip zone. The errors of rolling
cation of curve amplitude moves gradually towards the exit
force predicted by HM method are smaller than those
plane. The relative velocity gap of material and roll decrease
predicted by both Sims formula and eo formula.
with increasing Kp. The adhesion presents in the contact sur-
face when Kp = 1. In Fig. 4b, the specific roll pressure in-
creases with p because the larger p means the material has Acknowledgments The authors appreciate the financial support from
stronger ability to resist shear deformation. the National Natural Science Foundation of China (No: 51405353), the
Program for New Century Excellent Talents in University of Ministry of
The influence of the roll speed on the specific roll pressure Education of China (No: NCET-12-0715), the Natural Science
is shown in Fig. 5. For a given rolling process, the specific roll Foundation of Hubei Province (No: 2015CFB341), and the Cultivation
Int J Adv Manuf Technol
Program for Youth Elite in Wuhan University of Science and Technology
(No: 2015XZ2004).
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