41 A 250 mm wIde annea led bras5 70-30 5trip 15 ralled fram

thicknes5 of 20mm to l2 mm If the rolt radus 15 300mn

and the roll rpm 15 l0o.Estimate the tutal harsepower
reqired far thi5 uperatian Take K- 895 MPa,T- 0 49
Al Given Data,
Width, W= 250 mm
Intial thickness, t20mm
Final thicknes5, T- 12mm
Roll radius, R-3oomm
Rall RPM, N= loo pm
Strengyth Loefficient, K 895MPa
5train hardening exponent, n=049

5alUtion
Contact Length, L-R-)
300 (20-/2)
= 48.9qmm

True 5train,E= Int

T2
= In 20

12
= 051
Avernge flow Stress. Yp = ke"
1+n
049
895x051
+0 49
43228MPa
Rolling tore, F-Y4xwxL
432 28x 250x 48 99
52943493N
Tarque req to drive eAch roll,
T:05xFx
3
05x52943493x4899x |o
129685I Nm
Pawer (in kw) =
2x FLN
60000
F
3
2x314x 52943493x4849x |ox/o0
60000
2716-12 WRN6 kN
Power (in HP) = I34|x 2716 12
= 364232 HP
3 64 HP
Derive an analytical expressian for the magnu tude of
Back ten5ion in arder ta make the pOwered rall5 beg1n
to 5up
15 Too
H- Ro lls will begin to 5lip if the batk tension
neutral point
hi9n. 5ipping of the ro lls means thot the
whole con tact
ha5 moved to exit of the roll gop. Thes
area betomes the entty 2one.

Now
Let
= Flow5tress
M Cocfficient of tmchion
6 Beck tension
ho Initial thickness
he Final thickness

P Pre55ure
We khow that pressore in ety z0nt
P f-)hen[H-H
ho
NoW, When = 0, H- 0, Hence the pre5ure at et5,
e HH%
ho
Hlso. at the exit, the pressure is egual to Ye
4-4-)|be
eH

ho
 MHo HHo
he \e
ho ho
MHo MHo
heee
ho
ho
MHo
Divide both 5itès by hee
h
- MHo
hee
ho
AHo
-|h»\
he
where, H,- 2 R ton Ro\ with -
h he
Mex.pressure
Fressure

Y-
D1stance
Fg Effectof Beck&
frant tension
K3 AsStTIp with a
Cross RLton ot l5omn x 6mm 15 beng
alled wth 20o/ reduthm Ot ored uU5ing L4oom hameter
5teel rolls Before 8 after roling, the 5hearyield 5 tress
Of the matenol 15 035 KN/nm g 04KN/mn respertrvely
Calulate n the tial stnp thIcknes5 ,in the averoge
5hear yeld stress doring the proes5. Assume the Coeff
0f ficton to be 0.1

A-uiA5 widening i5 Cansidered during olling, 2096reducta-

na

the area implie5 a longrtucinal 5trein ot 02

In
itH

Cansenuent 20%reduction in the thidknes5. Thercfors

the finel 5trip thicK nes5 is given a5+
T 0 8ti =0 8x6 mm= 4 8mm

The averaqe 5hear yield

5tTes5 during the prore5 is
tii mean ot the initial
taken tD he the aith netit
5tre55. 5o,
the irel values of the yjeld

K- Kt Kf
2

=0 35+04
2

0375 KN/mm2

ot48mm
6

K-0375 KN/mm
Derive en for theaverage pe55ure
expres5Ion
in

Plen-5tain [opres5IGn With 5tickig tnttion

fichon refers to the tondi thon where a Tre5ca

H-5hicking
tTiction model is u5ed with m= 1.
M-

Where m -Sheer fector

C 5hear 5tremgth of the intertare
K-Sheer yield stres5

mK

+dx

y
From equilibrum in the X-directian,

Rtd)h +2mKdx-gh 0

5olving tor d
d 2 m k dx
h
Integraing
6R=2mhx+C
h
Where C i5 a Constant. The bouncery rondition is that
8T X=0, 5 =0,50 that,
 O:-2mk_a)t C
h

Theretore,
C 2mKa
h
&62mK(a-X)
h

Oie pressure,

Plain Strain,Y-2Y
.Bk
2
K

NoW
5mh (a-x)-Y
oy = y'1+mlb-x)
h

ND, 0X 43,
I ma+
h

SyY/Itma
2h
For Sticking, m=12
2h
5 Explan Tandem rolung, 5teckle rolling,Ring rolling&
With ncat sketche5
Thrcad rolling operathon5
A-I Tandem rolling

2 3 4 5 6
Stand1
30 I77 L 66 T 2
Jo 76 4 416 n
26s
ts
45 L Pay off
Take-upo18
Tke-up
rel 026 034 056 09
rel
45/225mm
Stond5 5tand 6
+ +
1

Fig.Taniem rullinq

x In tandem rolling, the 5trip i5 rolled continiosly thrugh

with each pas5
a number ot 5tand5 to thinner gage5

Each 5tand con5|5t5 Ot a 5et t rolls With its Dnn housing

and control5, a grDup 0t 5tands I5 called a train.
thicknes5 and the spæd at nhich
The control ot the 5trip
the trovels through eech roll gap i5 critical
Strip
Extensive electromc and Computer CDntrol5 are used in
these Dperators.
 2 5teckel rolling
CarerOrun Coler

Looper Roll5tand

Orwe
Input Roller [onveyor5 Output
-

Fio.5teckel Rollng
ued to feed the matenal
Coilers are
I n 5teckel mill two
thraugh mill.
+Une CDler is on the entrance side the other an the ew T

5Ide
the mill, 9 ten mateial
The coilers pull the matenal thmugh
desired
15 fed bech & forth thmu9h the mill unhl the
thickne s55 i5 reached
U5ed to proces5 5teel5labs into hot rolled ail.
I t is

3. Ring Ralling
i ver

weerperr
Fouding fD{i
-dleral
Workpiere-
doing rl

fig Rig Ralino

#In Ring Rolling, o 5mall diameter, thickring is expanded
into a large diameter thinner ring.
rolls,Dne otwhich is
+The ring is plated betwern twa rolls
thitkne55 is reduced by bringing the
dri vern. The
closer a5 they rotate.

4ThreedRalling Noving de

Blank
5tahamrydie-
a Flatdies
Norkpece Moung
5tahonar Cylindrial
die
irdnca
die
-Force

WorKrest

C7TwE raller dies

Fig Thred Rolling Processes
*The threads are formed an raund rods ar warkpieces by
passing tthem hetreen reciprucating a r rotatig dies.
+Typical procucts made by this prücess intlude 5crew5, botts,
and 5imi lar threedert parts.
The threed5 are generated without any loss ot metal & with
greater 5trengtth, becaLI5e Ct Cold wor king invalved

-X-