Rolling Process

Instructional Design Document

STAM Interactive Solutions

Demo Outline (For reference)

Topic Number 1 2 3 4

Topic Name Introduction Rolling Process Roll Gap Neutral Point

Page Type Animated page Animated page Animated page Animated page

5
6

Position of Neutral Point

Simulation

Animated page
Interactive page

Change Log (as per the minutes pdf)

Changes Suggested by Prof. Ramesh Singh Changes reflected on slide no.

1
2

Start with photo of real roll, voiceover to outline the process

Follow with schematic diagram listing process parameters (slide 15 of lecture notes at me.iitb.ac.in/~ramesh/me649/rolling.pdf) Show pressure distribution on the schematic (free body diagram / stresses and forces) Introduce neutral point

Slide 5 Also refer to the notes section

Slides 6, 7, 8 & 9 Also refer to the notes section

3 4

Voiceover to introduce objective of instruction feasibility for reduction / power Interactivity / animation Fix roll radius, back height and rotational speed of roll Enter hi and obtain maximum permissible hf Also show power required (using slides 35, 36, 55 and 56 of above cited lecture notes) Allow switch between 3 values for m: low, high and medium (use 0.1, 0.2 and 0.4) Assume steel properties (perfectly plastic) References Dont cite the wikipedia Add reference books as suggested Modify quiz question 1 - Spelling: affect vs. effect Modify quiz question 4 - All of above should be the correct answer

Slide 4 Text & Voice over changed Slide10 - Also refer to the notes section

Slide 11

Slide 12 & 15

Rolling Process

Advanced Manufacturing Process I & II

This demo illustrates the procedure for a 2-high rolling mill. Calculation of the maximum reduction that can be achieved and the power required to drive the rolling mill will be explained.

Rolling Process
Introduction

Advanced Manufacturing Process I & II

Rolling: Is the process of plastically deforming metal by passing it between rolls Is widely used to convert steel ingots into blooms, billets, and slabs, and subsequently into plates, sheets and strips

Advantages: Provides high throughput Provides good control over the dimensions of the finished product In Hot Rolling: Metal is rolled at a temperature above its recrystallization temperature Higher reduction in the cross-section is achieved In Cold Rolling: Metal is rolled at a temperature below its recrystallization temperature Better strength and control of dimensions are achieved

Rolling Process
Rolling Process

Advanced Manufacturing Process I & II

Rolls transfer energy to the strip through friction. As the strip is dragged by the rolls into the gap between them, it decreases in thickness while passing from the entrance to the exit. Meanwhile its speed gradually increases from the entrance to the exit.

V0 = input velocity Vf = final or output velocity R = roll radius hb = back height hf = output or final thickness

Rolling Process
Roll Gap

Advanced Manufacturing Process I & II

V0 = input velocity Vf = final or output velocity R = roll radius hb = back height hf = output or final thickness = = angle of bite L = Roll Gap

Rolling Process
Neutral Point

Advanced Manufacturing Process I & II

V0 = input velocity Vf = final or output velocity R = roll radius hb = back height hf = output or final thickness = = angle of bite N-N = neutral point or no-slip point L = Roll Gap
To the left of the Neutral Point: Velocity of the strip < Velocity of the roll To the right of the Neutral Point: Velocity of the strip > Velocity of the roll

Rolling Process
Position of the Neutral Point

Advanced Manufacturing Process I & II

As the neutral point reaches the exit, the rolls skid over the strip and the strip will stop moving. Maximum reduction is given by:

Rolling Process
Simulation

Advanced Manufacturing Process I & II

Back Height (hb): Neutral Point Roll Friction Coefficient ():

2 mm 0.1

Range (0.4mm to 10mm)

Constant

Flow stress of steel (Yflow) 130 Mpa Constant R Width of the Roller (W):
10 mm 75 mm Constant Constant

Roll Radius (R):

Rotational speed of Roll: hb hf m:

0.8 m/s Constant

0.1 0.2 0.4

START Sheet Final sheet thickness (hf): Roll Gap (L): Force/Roller (F): Power/Roller (P):

Enter the parameters and click START.

Rolling Process
Resources

Advanced Manufacturing Process I & II

Books: Serope Kalpakjian & Steven R. Schmid, Manufacturing Process for Engineering Materials, Section 6.3 Rolling Process Ghosh & Malik, Manufacturing Science

Rolling Process

Advanced Manufacturing Process I & II

The effect of friction on the rolling mill is

always bad since it retards exit of reduced metal always good since it drags metal into the gap between the rolls advantageous before the neutral point disadvantageous after the neutral point

Rolling Process

Advanced Manufacturing Process I & II

As compared to cold rolling, hot rolling yields

better dimensional control and higher strength better dimensional control but poorer strength
worse dimensional control and higher strength better dimensional control and poorer strength

Rolling Process

Advanced Manufacturing Process I & II

Velocity at the exit is

higher than velocity at the entry lower than velocity at the entry either equal to or lower than velocity at the entry, depending on the coefficient of friction either equal to or higher than velocity at the entry, depending on the coefficient of friction

Rolling Process

Advanced Manufacturing Process I & II

Power required depends upon

reduction of thickness width of metal / rolls

coefficient of friction metal type

Rolling Process

Advanced Manufacturing Process I & II

Reducing the rpm of the rolls

reduces the power required has no affect on the power required affects the power required depending on the coefficient of friction affects the power required depending on the properties of the metal