TUTORIAL QUESTIONS

MANU 2381
ROLLING

1. A 42.0 mm thick plate made of low carbon steel is to be reduced to 34.0 mm in one pass in a rolling
operation. As the thickness is reduced, the plate widens by 4%. The yield strength of the steel plate
is 174 MPa and the tensile strength is 290 MPa. The entrance speed of the plate is 15.0 m/min. The
roll radius is 325 mm and the rotational speed is 4.9 rev/min. Determine (a) the minimum required
coefficient of friction that would make this rolling operation possible, (b) exit velocity of the plate,
and (c) forward slip.
2. A 5 cm thick slab is 25 cm wide and 360 cm 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 and reduction, the slab will widen by 3% in each step. If the entry speed of the slab in
the first step is 12 m/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.
3. A series of cold rolling operations are to be used to reduce the thickness of a plate from 50 mm
down to 25 mm in a reversing two-high mill. Roll diameter = 700 mm and coefficient of friction
between rolls and work = 0.15. The specification is that the draft is to be equal on each pass.
Determine (a) minimum number of passes required, and (b) draft for each pass?
4. An annealed copper plate that is 250 mm wide and 25 mm thick is to be reduced in a single pass in
a two-high rolling mill to a thickness of 20 mm. The roll has a radius = 500 mm, and its speed = 30
m/min. Determine (a) roll force, (b) roll torque, and (c) power required to accomplish this operation.
5. Solve Problem 4 using a roll radius = 250 mm.
6. Solve Problem 4, only assume a cluster mill with working rolls of radius = 50 mm. Compare the
results with the previous two problems, and note the important effect of roll radius on force, torque
and power.
7. A 11.25 cm thick 1020 steel slab that is 22.5 cm wide and 60 cm long is to be reduced in a single
pass in a two-high rolling mill to a thickness of 9.675 cm. The roll rotates at a speed of 5.50 rev/min
and has a radius of 425 mm. Determine (a) roll force, (b) roll torque, and (c) power required to
accomplish this operation.
8. A single-pass rolling operation reduces a 20 mm thick brass plate to 18 mm. The starting plate is
200 mm wide. Roll radius = 250 mm and rotational speed = 12 rev/min. Determine (a) roll force,
(b) roll torque, and (c) power required for this operation.
Figure 2.5: True stress true strain curves
 HOMEWORK 3
MME 2101
ANSWERS
1. A 42.0 mm thick plate made of low carbon steel is to be reduced to 34.0 mm in one pass in a rolling
operation. As the thickness is reduced, the plate widens by 4%. The yield strength of the steel plate
is 174 MPa and the tensile strength is 290 MPa. The entrance speed of the plate is 15.0 m/min. The
roll radius is 325 mm and the rotational speed is 4.9 rev/min. Determine (a) the minimum required
coefficient of friction that would make this rolling operation possible, (b) exit velocity of the plate,
and (c) forward slip.
Solution: (a) Maximum draft dmax = 2 R
Given that d = to - tf = 42 - 34 = 8.0 mm,
2 = 8/325 = 0.0246
= (0.0246)0.5 = 0.157
(b) Plate widens by 4%.
towovo = tfwfvf
wf = 1.04 wo
42(wo)(15) = 34(1.04wo)vf
vf = 42(wo)(15)/ 34(1.04wo) = 630/35.4 = 17.8 m/min
(c) vr = 2 rN = 2(0.325)(4.9) = 10 m/min
s = (vf - vr)/vr = (17.8 10)/10 = 0.78

2. A 5 cm thick slab is 25 cm wide and 360 cm 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 and reduction, the slab will widen by 3% in each step. If the entry speed of the slab in
the first step is 12 m/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.
Solution: (a) After three passes, tf = (0.75)(0.75)(0.75)(5.0) = 2.11 cm
wf = (1.03)(1.03)(1.03)(25.0) = 27.32 cm
towoLo = tfwfLf
(5)(25)(360) = (2.11)(27.32)Lf
Lf = (5)(25)(360)/(2.11)(27.32) = 780.64 cm
(b) Given that roll speed is the same at all three stands and that towovo = tfwfvf ,
Step 1: vf = (0.05)(0.25)(12 m/min)/(0.75 x 0.05)(1.03 x 0.25) = 15.53 m/min
Step 2: vf = (0.75 x 0.05)(1.03 x 0.25)(12)/(0.752 x 0.05)(1.032 x 0.25) = 15.53 m/min
Step 3: vf = (0.752 x 0.05)(1.032 x 0.25)(40)/(0.753 x 0.05)(1.033 x 0.25) = 15.53 m/min
3. A series of cold rolling operations are to be used to reduce the thickness of a plate from 50 mm
down to 25 mm in a reversing two-high mill. Roll diameter = 700 mm and coefficient of friction
between rolls and work = 0.15. The specification is that the draft is to be equal on each pass.
Determine (a) minimum number of passes required, and (b) draft for each pass?
Solution: (a) Maximum draft dmax = 2 R = (0.15)2 (350) = 7.875 mm
Minimum number of passes = (to - tf)/dmax = (50 - 25)/7.875 = 3.17 4 passes

(b) Draft per pass d = (50 - 25)/4 = 6.25 mm

4. An annealed copper plate that is 250 mm wide and 25 mm thick is to be reduced in a single pass in
a two-high rolling mill to a thickness of 20 mm. The roll has a radius = 500 mm, and its speed = 30
m/min. Determine (a) roll force, (b) roll torque, and (c) power required to accomplish this operation.
Solution: (a) Draft d = 25 - 20 = 5 mm,
Contact length L = (500 x 5).5 = 50 mm
True strain = ln(25/20) = ln 1.25 = 0.223
From graph: at = 0, Yi= 75.67 MPa (70-80 MPa acceptable)
at = 0.223, Yf= 286.47 MPa (270-290 MPa acceptable)
Y avg = (Yi+ Yf)/2 = 181 MPa (170-190 MPa acceptable)
Rolling force F = LwYavg
= (250)(50) (181) = 2262500 N (2125000 2375000 N acceptable)

(b) Torque T = 0.5 FL

= 0.5(2262500)( 50 x 10-3) = 56562.5 N-m ( 53125 59375 Nm acceptable)

(c) vr = 2 rN

N= vr / (2 r)

N = (30 m/min)/(2 x 0.500) = 9.55 rev/min = 0.159 rev/s

Power P = 2FLN
= 2(2262500)(50 x 10-3) (0.159)
= 113k N-m/s = 113k W ( 106 118 kW acceptable)
5. Solve Problem 4 using a roll radius = 250 mm.
Solution: (a) Draft d = 25 - 20 = 5 mm,
Contact length L = (250 x 5).5 = 35.35 mm
True strain = ln(25/20) = ln 1.25 = 0.223

Rolling force F = LwYavg

F = 181(250)(35.35) = 1599587.5N (1502375 1697125 N acceptable)
(b) Torque, T = 0.5 FL
= 0.5(1599587.5)(35.35 x 10-3) = 28272.7 N-m (26554.5 29996.7 acceptable)
(c) N = (30 m/min)/(2 x 0.250) = 19.1 rev/min = 0.318 rev/s
Power P = 2 FLN
= 2(0.318)(1599587.5)(35.35 x 10-3)
= 113 k N-m/s = 113k W ( 106 118 kW acceptable)
Note that the force and torque are reduced as roll radius is reduced, but that the power remains
the same (within calculation error) as in the previous problem.

6. Solve Problem 4, only assume a cluster mill with working rolls of radius = 50 mm. Compare the
results with the previous two problems, and note the important effect of roll radius on force, torque
and power.
Solution: (a) Draft d = 25 - 20 = 5 mm,
Contact length L = (50 x 5).5 = 15.81 mm
True strain = ln(25/20) = ln 1.25 = 0.223

Rolling force F = LwYavg

= 181(250)(15.81) = 715402.5N (671925 750975 N acceptable)

(b) Torque T = 0.5 FL
= 0.5(715402.5)(15.81 x 10-3) = 5655.3N-m ( 5311.6 5936.5 Nm acceptable)
(c) N = (30 m/min)/(2 x 0.050) = 95.5 rev/min = 1.592 rev/s
Power P = 2 FLN
=2(1.592)(715402.5)(15.81 x 10-3)
= 113k N-m/s = 113k W ( 106 118 kW acceptable)
7. A 11.25 cm thick 1020 steel slab that is 22.5 cm wide and 60 cm long is to be reduced in a single
pass in a two-high rolling mill to a thickness of 9.675 cm. The roll rotates at a speed of 5.50 rev/min
and has a radius of 425 mm. Determine (a) roll force, (b) roll torque, and (c) power required to
accomplish this operation.
Solution: (a) Draft d = 112.5 96.75 = 15.75 mm
Contact length L = (425 x 15.75)0.5 = 81.81 mm
True strain = ln(112.5/96.75) = ln 1.16 = 0.1508

From graph: at = 0, Yi= 124.3 MPa (115-135 MPa acceptable)

at = 0.1508, Yf= 400 MPa (390-410 MPa acceptable)
Y avg = (Yi+ Yf)/2 = 262.15 MPa (250-270 MPa acceptable)

Rolling force F = Y avg wL

= 262.15 MPa (2.25m)(0.8181m)
= 482.5 MN (460 497 MN acceptable)

(b) Torque T = 0.5FL = 0.5(482.5MN)(0.8181 m)

= 197.4 MNm (188-203 MNm acceptable)
(c) Power P = 2 FLN = 2(482.5MN)(0.8181 m )(5.5 /60 rev/s)
= 227.35 MW (216.7 234.2 MW acceptable)

8. A single-pass rolling operation reduces a 20 mm thick brass plate to 18 mm. The starting plate is 200
mm wide. Roll radius = 250 mm and rotational speed = 12 rev/min. Determine (a) roll force, (b) roll
torque, and (c) power required for this operation.
Solution: (a) Draft d = 20 - 18 = 2.0 mm,
Contact length L = (250 x 2).5 = 11.18 mm = 0.0112 m
True strain = ln(20/18) = ln 1.111 = 0.1054

From graph: at = 0, Yi= 254 MPa (240-260 MPa acceptable)

at = 0.1054, Yf= 345.92 MPa (335-355 MPa acceptable)
Y avg = (Yi+ Yf)/2 = 300 MPa (290-310 MPa acceptable)

Rolling force F = Yavg Lw =300(0.0112)(0.2)

= 0.672 MN = 672,000 N ( 0.64 1.736 MN acceptable)

(b) Torque T = 0.5 FL = 0.5(672,000)(0.0112) = 3,720 N-m (3584 9721.6 Nm acceptable)

(c) Given that N = 12 rev/min
Power P = 2(12/60)(672,000)(0.0112) = 9457.95 W ( 9007.6 24433 W acceptable)