7/24/2011

GATE2008

Rolling
BySKMondal

In a single pass rolling operation, a 20 mm thick plate with plate width of 100 mm, is reduced to 18 mm. The roller radius is 250 mm and rotational speed is 10 rpm. The average flow stress for the plate material is 300 MPa. The power required for the rolling operation in kW is closest to (a) 15.2 (b) 18.2 (c) 30.4 (d) 45.6 Ans. (a)

GATE2007
The thickness of a metallic sheet is reduced from an initial value of 16 mm to a final value of 10 mm in one single pass rolling with a pair of cylindrical rollers each of diameter of 400 mm. The bite angle in degree will be (a) 5.936 (b) 7.936 (c) 8.936 (d) 9.936 Ans. (d)

GATE2004
In a rolling process, sheet of 25 mm thickness is rolled to 20 mm thickness. Roll is of diameter 600 mm and it rotates at 100 rpm. The roll strip contact length will be (a) 5 mm (b) 39 mm (c) 78 mm (d) 120 mm Ans. (b)

GATE1998
A strip with a crosssection 150 mm x 4.5 mm is being rolled with 20% reduction of area using 450 mm diameter rolls. The angle subtended by the deformation zone at the roll centre is (in radian) (a) 0.01 (b) 0.02 0 01 0 02 (c) 0.03 (d) 0.06 Ans. (d)

GATE2006
A 4 mm thick sheet is rolled with 300 mm diameter rolls to reduce thickness without any charge in its width. The friction coefficient at the workroll interface is 0.1. The minimum possible thickness of the sheet that can be produced in a single pass is (a) 1.0 mm (b) 1.5 mm (c) 2.5 mm (d) 3.7 mm Ans. (c)

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IES 2003
Assertion (A): While rolling metal sheet in rolling mill, the edges are sometimes not straight and flat but are wavy. Reason (R): Nonuniform mechanical properties of the flat material rolled out result in waviness of the edges. (a) Both A and R are individually true and R is the correct explanation of A (b) Both A and R are individually true but R is not the correct explanation of A (c) A is true but R is false (d) A is false but R is true [Ans. (c)]

IES 2002
In rolling a strip between two the neutral point in the arc depend on (a) Amount of reduction (b) (c) Coefficient f friction (d) ( ) C ffi i t of f i ti Ans. (d) rolls, the position of of contact does not Diameter of the rolls Material f the ll M t i l of th rolls

IES 2001
Which of the following assumptions are correct for cold rolling? 1. The material is plastic. 2. The arc of contact is circular with a radius greater than the radius of the roll. 3. Coefficient of friction is constant over the arc of contact and acts in one direction throughout the arc of contact. Select the correct answer using the codes given below: Codes: (a) 1 and 2 (b) 1 and 3 (c) 2 and 3 (d) 1, 2 and 3 [Ans. (a)]

IES 2001
A strip is to be rolled from a thickness of 30 mm to 15 mm using a twohigh mill having rolls of diameter 300 mm. The coefficient of friction for unaided bite should nearly be (a) 0 35 0.35 (b) 0 5 0.5 (c) 0.25 (d) 0.07 Ans. (a)

IES 2000
In the rolling process, roll separating force can be decreased by (a) Reducing the roll diameter (b) Increasing the roll diameter (c) Providing backup rolls (d) Increasing the friction between the rolls and the metal Ans. (a)

IES 1999
Assertion(A):Inatwohighrollingmillthereisa limittothepossiblereductioninthicknessinone pass. Reason(R):Thereductionpossibleinthesecond passislessthanthatinthefirstpass. passislessthanthatinthefirstpass (a) BothAandRareindividuallytrueandRisthe correctexplanationofA (b) BothAandRareindividuallytruebutRisnot the correctexplanationofA (c) AistruebutRisfalse (d) AisfalsebutRistrue [Ans.(b)]

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IES 1993
In order to get uniform thickness of the plate by rolling process, one provides (a) Camber on the rolls (b) Offset on the rolls (c) Hardening of the rolls (d) Antifriction bearings Ans. (a)

IES 1993
The blank diameter used in thread rolling will be (a) Equal to minor diameter of the thread (b) Equal to pitch diameter of the thread (c) A little large than the minor diameter of the thread (d) A little larger than the pitch diameter of the thread Ans. (d)

IES 1992
Threadrollingisrestrictedto (a) Ferrousmaterials (b) Ductilematerials (c) Hardmaterials (d) Noneoftheabove Ans.(b)

IAS 2004
Assertion (A): Rolling requires high friction which increases forces and power consumption. Reason (R): To prevent damage to the surface of the rolled products, lubricants should be used. (a) Both ( ) B th A and R are i di id ll t d individually true and R i th d is the correct explanation of A (b) Both A and R are individually true but R is not the correct explanation of A (c) A is true but R is false (d) A is false but R is true [Ans. (b)]

IAS 2001
Consider the following characteristics of rolling process: 1. Shows work hardening effect 2. Surface finish is not good 3. Heavy reduction in areas can be obtained Which of these characteristics are associated with hot rolling? (a) 1 and 2 (b) 1 and 3 (c) 2 and 3 (d) 1, 2 and 3 Ans. (c)

IAS 2000
Rollingverythinstripsofmildsteelrequires (a) Largediameterrolls (b) Smalldiameterrolls (c) Highspeedrolling (d) Rollingwithoutalubricant Ans.(b)

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IAS 1998
Match List I (products) with List II (processes) and select the correct answer using the codes given below the lists: List I List II A. M.S. angles and channels 1. Welding A MS l d h l W ldi B. Carburetors 2. Forging C. Roof trusses 3. Casting D. Gear wheels 4. Rolling [Ans. (d)] Codes:A B C D A B C D (a) 1 2 3 4 (b) 4 3 2 1 (c) 1 2 4 3 (d) 4 3 1 2

IAS 2007
Match List I with List II and select the correct answer using the code given below the Lists: List I List II (Type of Rolling Mill) (Characteristic) A. Two high nonreversing mills 1. Middle roll rotates by friction B. Th Three hi h mills high ill 2. B small working roll, power By B ll ki ll for rolling is reduced C. Four high mills 3. Rolls of equal size are rotated only in one direction D. Cluster mills 4. Diameter of working roll is very small [Ans. (d)] Code:A B C D A B C D (a) 3 4 2 1 (b) 2 1 3 4 (c) 2 4 3 1 (d) 3 1 2 4

IAS 2003
In one setting of rolls in a 3high rolling mill, one gets (a) One reduction in thickness (b) Two reductions in thickness (c) Three reductions in thickness (d) Two or three reductions in thickness depending upon the setting Ans. (b)

IAS 2007
Consider the following statements: Roll forces in rolling can be reduced by 1. Reducing friction 2. Using large diameter rolls to increase the contact area. 3. Taking smaller reductions per pass to reduce the contact area. Which of the statements given above are correct? (a) 1 and 2 only (b) 2 and 3 only (c) 1 and 3 only (d) 1, 2 and 3 [Ans. (c)]

GATE2011
The maximum possible draft in cold rolling of sheet increases with the (a) increase in coefficient of friction (b) decrease in coefficient of friction (c) decrease in roll radius (d) increase in roll velocity Ans. (a)

Analysis of Rolling

Fig. Geometry of Rolling Process

Total reduction or draft taken in rolling.

h = he - h1 = 2 (R - R cos a) = D (1 - cos a)
Usually, the reduction in blooming mills is about 100 mm and in slabbing mills, about 50 to 60 mm. The projected length if the arc of contact is,

l = R.sin a

or l =
l=

BC 2 - CE 2
R.h - ( 0.5 h )
2
2

Now BC = R.h and CE = R (1 - cos a) (1 - cos a) = 0.5 h

P= Usually, ( 0.5h ) is < R h

l
Assumption in Rolling

( R h )1/2

1. Rolls are straight, rigid cylinders. 2. Strip is wide compared with its thickness, so that no widening of strip occurs (plane strain conditions). 3. The material is rigid perfectly plastic (constant yield strength). 4. The co-efficient of friction is constant over the tool- work interface.

Fig. Stress Equilibrium of an Element in Rolling Considering the thickness of the element perpendicular to the plane of paper to be unity, We get equilibrium equation in x-direction as,

- l h + (l +dl ) (h + dh) - 2P R d sin +2 l R d cos = 0

For sliding friction, = p . Simplifying and neglecting second order terms, we get

d (x h ) d p x =

= 2pR( ) 2 3 0 = '0

d h p '0 = 2pR ( ) d d ' p 0 h ' 1 = 2pR ( ) d 0

d ' d p p 0 h = 2pR ( ) ' + ' 1 d 0 0 d Due to cold rolling, '0 increases as h decreases, thus '0 h nearly a constant and its derivative zero. '0 h

d p / '0 2R = ( ) d p / 0 h h = h f + 2R (1 cos ) = h f + R2 d p / '0

' 0

(p / ) (

)= )

2R ( ) d h f + R2 2Rd h f + R2

Integrating both side ln p / '0 =

2R d 2 f + R 2d h = ln R

= I II I=

2Rd = 2 f + R h/R =

2Rd = h

h/R

hf + 2 R

= 2 2R II = d h f + R2
= = 2

d hf d R

2 d / R + 2

R R .tan 1 . hf hf

h ln p / '0 = ln 2 R

R .tan 1 hf

R . + ln C hf

h p = C '0 e H R where H = 2 R .tan 1 hf R .. hf

Now at entry , = Hence H = H0 with replaced by in above equation At exit = 0 ,H = H1 = 0 There for p = '0

h In the entry zone p = C. '0 o e Ho R

C=

R Ho .e ho h H H . e ( 0 ) h0 h p = '0 hf
hn H H . e ( 0 n) h0 or

p = '0

In the exit zone H .e h = n . e Hn hl

ho H 2H = e ( 0 n) hf h 1 1 H0 ln 0 2 hf R .tan 1 hf R .. hf

or Hn =

from H = 2 n =

h f Hn hf .tan . R 2 R hn = h f + 2R (1 cos n )

Maximum Draft. It has already been proved that if the strip is to enter the rolls unaided then, the following relation has to be satisfied between the angle of bite and co-efficient of friction between the roll and material surfaces.

> tan a

Now, from Fig. 13.12, the projected length of are of contact,

l = R.h, and h 2 Since R > > 0.5 h, it can be written that Rtan a = l = R h R 05 h

tan a =
Since tan a

h R

The maximum draft is given by

or,

h R

( h )max

= 2R

Q.1. In rolling process, 25 mm thick plate is rolled to 20 mm in a four high mill. Determine the coefficient of friction if this is the maximum reduction possible. Roll diameter is 500 mm. Find neutral Section, Back word and forward slip sad maximum pressure, o = 100 N / mm 2 for hot rolls of middle steel at about 1100oC. Solution: h = 2 R (i).

( 25 20 ) = 0.142 h = R 250 and h = 2R (1 cos )

or = or 5 = 500 (1 cos ) = 8.110 = 0.1429

(ii)

H0 = 2

R . h f 250 250 . tan 1 = 2. 0.1429 = 3.306 20 20 R .tan 1 hf

Hn = = n = =

h0 1 1 H0 log e 2 hf 1 1 25 3.306 0.142 .log e 20 = 0.8678 2 h f Hn hf .tan . R 2 R 20 0.8678 250 tan 20 250 2

= 0.0349 rad hn = h f + 2R (1 cos n ) = h f + Rn 2 = 20 + 250 ( 0.0349 ) = 20.3mm

2

(iii)

Backward slip = Forward slip =

Vr V0 V h 20.3 =1 0 =1 n =1 = 18.8% Vr Vr h0 25

Vf Vr Vf h 20.3 = 1 = n 1 = 1 = 1.5% Vr Vr hf 20

Vo Vr N

Vf

(iv) pmax = pn = 0

h n Hn .e hf 2 20.3 0.142 0.8678 .100 .e = = 132.4 N / mm2 20 3

Q2. Sheet steel is reduced from 4.05 mm to 3.55 mm with 500 mm diameter rolls having a coefficient of fiction of 0.04. The mean flow stress in tension is 210 N/mm2. Neglect work hardening and roll flattening. (a) Calculate the roll pressure at the entrance to the rolls, the neutral plane, and the roll exit. (b) If the co-efficient of friction is 0.40, determine the roll pressure at the neutral point. (c) If 35 N/mm2 front tensions are applied in the problem find the roll pressure at the neutral point.
Solution: Given ho = 4.05 mm hf = 3.55 mm R = 250 mm, = 0.04, 0 = 210 N / mm2

(a) The roll pressure at entry and exit, 2 p = = 0 = 242.5N / mm2 0 3 R R H0 = 2 .tan 1 Now h hf f 250 250 H0 = 2 .tan 1 0.0447 3.55 3.55 = 6.02

Hn = =

ho 1 1 H0 log e 2 hf 1 1 4.05 6.02 0.04 log e 3.55 = 1.363 2 h n Hn .e hf

pn = . 0
Now

n =

h f Hn 3.55 hf 3.55 .tan . .tan = 0.6815 = 0.009672 rad. = 0.5540 250 R 2 R 250

And

h = 2R (1- cos) (4.05-3.55) = 2 250 (1- cos ) or = 2.56o = 0.0447 rad. = 3.55 +2 250 (1- cos 0.554o)

h n = h f + 2R (1 cos n )
= 3.5734 mm h pn = . n .e Hn 0 hf

= 242.5

3.5734 0.041.363 = 257.78 N / mm2 e 3.55

( b ) H0 = 6.02 ( earlier )
= 0.4 then Hn = n = 1 1 4.05 6.02 0.4 log e 3.55 = 2.845 2 3.55 3.55 1.4225 = 0.02rad tan 250 250
2

2 h n = h f + Rn

= 3.55 + 250 ( 0.02 ) = 3.65 mm pn = . 0 hn . e Hn hf

3.65 0.042.845 e = 777.9N / mm2 3.55 h (c) pn = ( f ) . n . e Hn 0 hf = 242.5 = ( 242.5 35 ) 3.5734 0.041.363 e = 220.57 N / mm2 3.55

Q 3. A wide-strip is rolled to a final thickness of 6.35 mm will a reduction of 30 percent. The roll radius is 50 cm and the co-efficient of friction is 0.2. Determine the neutral plane. Solution:

hf = 6.35mm, R = 50cm = 500mm, = 0.2 100 ho = hf = 9.07mm 70 h = h0 h f = 9.07 6.35 = 2.72mm

h = 2R (1 cos )

2.72 = 2 500 (1 cos ) or = 4.230 = 0.0738 rad.

Now

H0 = 2. = 2

R R .tan 1 . h hf f 500 500 tan 1 0.0738 6.35 6.35

= 10.29.

now Hn =

h0 1 1 1 1 9.07 log e H0 log e = 10.29 = 4.26 2 0.2 6.35 hf 2

h f Hn hf .tan . R 2 R 6.35 6.35 tan 2.13 = 0.0273 rad = 1.550 500 500

n = =

Q.4. A metal strip is to be rolled from an initial wrought thickness of 3.5 mm to a final rolled from an initial wrought thickness of 2.5 mm in a single pass rolling mill having rolls of 250 mm diameter. The strip is 450 mm wide. The average co-efficient of friction in the roll gap is 0.08. Taking plain strain flow stress of 140 MPa, for the metal and assuming neglecting spreading, estimate the roll separating force. [GATE-1997]
Solution Hint: We know p= p = l. bm pm Use.
h h0 h0 1 n pdh + pdh + h p.dh b h hl hn

pm =

Torque and Power

The power is spent principally in four ways 1) The energy needed to deform the metal. 2) The energy needed to overcome the frictional force. 3) The power lost in the pinions and power-transmission system. 4) Electrical losses in the various motors and generators. Remarks: Losses in the windup reel and uncoiler must also be considered.

The total rolling load is distributed over the arc of contact in the typical friction-hill pressure distribution. However the total rolling load can be assumed to be concentrated at a point along the act of contact at a distance a from the line of centres of the rolls. The ratio of the moment arm a to the projected length of the act of contact Lp can be given as

a = LP

a R h

Where is 0.5 for hot-rolling and 0.45 for cold-rolling. The torque MT is equal to the total rolling load P multiplied by the effective moment arm a. Since there are two work rolls, the torque is given by MT = 2Pa During one revolution of the top roll the resultant rolling load P moves along the circumference of a circle equal to 2a. Since there are two work rolls, the work done W is equal to

Work = 2(2 a)P

Since power is defined as the rate of doing work, i.e., 1 W = 1 J s-1, the power (in watts) needed to operated a pair of rolls revolving at N Hz (s-1) in deforming metal as it flows through the roll gap is given by W = 4 aPN Where P is in Newtons and a is in metre.