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Procedia Manufacturing 15 (2018) 59–64
Procedia Manufacturing 00 (2017) 000–000
www.elsevier.com/locate/procedia
17th International Conference on Metal Forming, Metal Forming 2018, 16-19 September 2018,
17th International Conference on MetalToyohashi,
Forming, Metal
Japan Forming 2018, 16-19 September 2018,
Toyohashi, Japan
Thermal properties of oxide scale on surface of work roll in hot
Thermal properties
Manufacturing of oxide
Engineering Society scale Conference
International on surface of work roll in hot
rolling mill Spain2017, MESIC 2017, 28-30 June
rolling mill
2017, Vigo (Pontevedra),
Nobuki Yukawa*, Eiji Abe, Shohei Fujiwara
Costing models for capacity
Nobuki Yukawa*, optimization
Eiji Abe, Shohei in Fujiwara
Industry 4.0: Trade-off
between Nagoya
usedUniversity,
capacity and operational
Furocho, chikusa-ku, efficiency
Nagoya University, Furocho, chikusa-ku, Nagoya 464-8603, Japan
Nagoya 464-8603, Japan

Abstract A. Santanaa, P. Afonsoa,*, A. Zaninb, R. Wernkeb

Abstract
In hot rolling processes, an accurate prediction a of thermal
University of Minho,expansion of work rolls
4800-058 Guimarães, is important because it affects the profile and
Portugal
In hot
the rolling
shape processes,
of rolled strips.an accurate of
Prediction prediction
thermal
b of thermal
expansion
Unochapecó, expansion
requires
89809-000 an of work
SC,rolls
interface
Chapecó, heatistransfer
Brazil important becausebetween
coefficient it affectsthe
therolls
profile
andand
the
the shape
strips. of rolled
Oxide strips.
scale on Prediction
the surface of work
of the thermalrollexpansion
(mill scale)requires an the
is one of interface heatfactor
important transfer
thatcoefficient
affects thebetween the rolls
heat transfer and the
coefficient.
strips. Oxide
Although scale
clear on the
relation surfacethe
between of the
millwork
scaleroll
and(mill scale)
the heat is one coefficient
transfer of the important factor itthat
is required, hasaffects the heatbecause
not clarified transferforming
coefficient.
mill
Although
scale clear relation
in a laboratory betweenInthe
is difficult. mill
this scalemill
study, andscale
the heat transfer
is formed bycoefficient is required,
axis compression it has not
experiment in aclarified because
laboratory. The forming mill
heat transfer
scale in a laboratory
coefficients
Abstract is difficult.
of mill scale In this study,
are measured. mill scale
The relation is formed
between by axis
the heat compression
transfer experiment
coefficient in a laboratory.
and the thickness The heat
of mill scale transfer
is obtained.
coefficients of mill scale are measured. The relation between the heat transfer coefficient and the thickness of mill scale is obtained.
© 2018 the
Under The Authors. Published
concept Published
of "Industryby Elsevier
4.0", B.V.
production processes will be pushed to be increasingly interconnected,
© 2018 The Authors. by Elsevier B.V.
© 2018 The Authors.
Peer-review Published by of Elsevier B.V. committee of the 17th International Conference on Metal Forming.
Peer-review under
information under responsibility
basedresponsibility
on a real time
of the
the scientific
basis and,
scientific necessarily,
committee much
of the 17thmore efficient.
International In this context,
Conference on Metalcapacity
Forming. optimization
Peer-review under responsibility of the scientific committee of the 17th International Conference on Metal Forming.
goes beyond the traditional aim of capacity maximization, contributing also for organization’s profitability and value.
Keywords: Hot rolling; Thernal expansion; Heat transfer cofficient; Mill scale
Indeed,
Keywords:lean management
Hot rolling; and continuous
Thernal expansion; improvement
Heat transfer cofficient; approaches suggest capacity optimization instead of
Mill scale
maximization. The study of capacity optimization and costing models is an important research topic that deserves
contributions
1. Introduction from both the practical and theoretical perspectives. This paper presents and discusses a mathematical
model for capacity management based on different costing models (ABC and TDABC). A generic model has been
1. Introduction
developed
In recentand it was
years, theused to analyze idle
requirements capacity
to the qualityandof to design
rolled strategies
products towards
become the maximization
higher and higher. The of organization’s
shape and the
value. The
recent trade-off
years, thecapacity maximization
requirements to the vs operational
quality of rolled efficiency
products is
becomehighlighted
profile of the rolled strips are affected by the work roll profile. Thus, an accurate prediction of thermalshape
In higher and
and it is
higher. shown
The that capacity
and the
expansion of
optimization
profile of the might
rolled
the work roll is important.hide operational
strips are affectedinefficiency.
by the work roll profile. Thus, an accurate prediction of thermal expansion of
the2017
© workTheroll is important.
Authors. Published by Elsevier B.V.
Recently, high speed steel (HSS) rolls have been used for the former stands of the finishing mills in a hot rolling
Peer-review
line, as theyunder
Recently, highresponsibility
have speed steel
excellent of the scientific
(HSS)
mechanical rolls committee
have been
properties, i.e., of
used the
forManufacturing
hardness theand
former Engineering
wearstands Society
of theHowever,
resistance. finishingInternational
itmills in aConference
has been hot rolling
difficult to
2017.
line, as they have excellent mechanical properties, i.e., hardness and wear resistance. However,
use for the later stand of the finishing mills because the HSS rolls have higher thermal expansion than conventional it has been difficult to
use
workforrolls
the [1,
later2].stand of the finishing
Therefore, an accurate mills because the
calculation of HSS
thermal rollsexpansion
have higher thermal expansion
is required. When the than workconventional
roll surface
Keywords:
work rollsCost[1,Models; ABC; TDABC;
2]. Therefore, Capacity Management;
an accurate calculationIdle ofCapacity;
thermalOperational
expansion Efficiency
is required. When the work roll surface

1. Introduction
* Corresponding author. Tel.: +81-52-789-3572; fax: +81-52-789-3574
* E-mail
Corresponding
address:author. Tel.: +81-52-789-3572; fax: +81-52-789-3574
yukawa@numse.nagoya-u.ac.jp
The cost
E-mail of idle
address: capacity is a fundamental information for companies and their management of extreme importance
yukawa@numse.nagoya-u.ac.jp
in modern©production
2351-9789 systems.
2018 The Authors. In general,
Published it isB.V.
by Elsevier defined as unused capacity or production potential and can be measured
Peer-review
in underThe
several©ways:
2351-9789 2018 responsibility
tons of theby
of production,
Authors. Published scientific committee
available
Elsevier B.V.hours of the 17th International
manufacturing, etc.Conference on Metal Forming.
The management of the idle capacity
Peer-review under
* Paulo Afonso. responsibility
Tel.: +351 253 510of thefax:
761; scientific
+351 253committee
604 741 of the 17th International Conference on Metal Forming.
E-mail address: psafonso@dps.uminho.pt

2351-9789 © 2017 The Authors. Published by Elsevier B.V.

Peer-review under responsibility of the scientific committee of the Manufacturing Engineering Society International Conference 2017.
2351-9789 © 2018 The Authors. Published by Elsevier B.V.
Peer-review under responsibility of the scientific committee of the 17th International Conference on Metal Forming.
10.1016/j.promfg.2018.07.170
60 Nobuki Yukawa et al. / Procedia Manufacturing 15 (2018) 59–64
2 Nobuki Yukawa, Eiji Abe, Shohei Fujiwara/ Procedia Manufacturing 00 (2018) 000–000

contacts to the surface of strips, a heat transfer occurs from the strip to the work roll through oxide scale on the strip
and on the work roll (mill scale). These scales have an insulating effect because the oxide scale has lower thermal
conductivity than steel [3]. In the previous work [4], the heat transfer coefficient of the oxide scale on the strip was
measured and modeled. However, the thermal properties of the mill scale have not been precisely measured.
The thickness of mill scale obviously affects the heat transfer coefficient. Therefore, for an accurate thermal
expansion calculation, it is important to to clarify the relation between the heat transfer from the strip to the work roll
and the thickness of the mill scale. However, it has not been clarified that relation because it is difficult to produce a
mill scale in a laboratory.
This study consists of two parts. First, we developed a generating method of the mill scale of hot rolling mill in a
laboratory. Uniaxial compression contact experiments are used to simulate the contact between the work roll and the
strip during the hot rolling. An oxide scale layer that simulates the mill scale was obtained on the surface of punch
by this experiment. The thickness of mill scale which was generated from the different kinds of strips was measured.
Second, the interface heat transfer coefficient for various thickness of mill scale are measured. From these results,
the relation between the thickness of mill scale and the heat resistance is clarified.

2. Experiment of generating mill scale

2.1. Experiment procedure

In this experiment, the mill scale is formed by uni-axis compression contact experiment in a laboratory. Fig.1
shows the schematic view of the experiment. High speed steel SKH51 (JIS) is used for punch and S45C (JIS) and
SUS310S (JIS) are used for the workpieces. The punch is a cylindrical column, which dimensions are Φ24 mm in
diameter and 30mm in height. The workpiece is also a cylindrical column, which dimensions are Φ27 in diameter and
20 mm in height. Punch surface and strip surface are polished to reduce surface roughness.
Uniaxial compression contact experiment has 5 steps. First, workpieces are heated to 1180 ˚C and held for 20
min in an air atmosphere furnace. Second, workpieces are moved onto the alumina plate in 4 sec. Third, the surface
oxide scale on the workpieces are removed by blowing water and hitting metal with a steel stick. This procedure
simulates the descaling process in actual hot rolling. Forth, workpieces are moved onto the bottom die in 3 sec, and
the punch with sprayed water on the surface is contacted with 50 MPa contact pressure. Total time from picking up
workpieces to contacts is 10 sec. Table 1 shows the number of contacts and the contact time for each contact. This
5step procedure repeats every one minute cycle. After the formation of oxide scale on the punch, the component of
the mill scale is analysed by XRD and the cross section of the oxide scale is observed by SEM. The thickness of the
scale is measured from this image data.

Fig. 1. Experiment configuration; (a) schematic view of actual rolling; (b) photo of experiment; (c) cross section of experiment.
 Nobuki Yukawa et al. / Procedia Manufacturing 15 (2018) 59–64 61
Author name / Procedia Manufacturing 00 (2018) 000–000 3

Table 1. Experimental conditions.

Contact Numeber of contacts

time 10 20 24 30 40 60
3sec ● ● ● ●
4sec ● ●
5sec ● ●

2.2. Result and discussions

Fig. 2(a), (b) shows the XRD spectrum of the punch surface ((a) workpiece S45C (b) workpiece SUS310S). The
X-ray analysis indicates that there are three kinds of oxides (FeO, Fe2O3 and Fe3O4). In both cases, main component
is Fe3O4. Thus, it concerns that compression experiment forms mill scale which has same component as actual mill
scale [5]. Fig. 3(a), (b) shows SEM image of cross section of oxide scale. Average thickness of the mill scale is
measured from these images. Fig. 4 shows the thickness of oxide scale in every experiment conditions. It can be seen
from this figure that the thickness of the mill scale formed with S45C workpiece is thicker than that with SUS310S.
Furthermore, the more the number of contacts increase, the thicker the mill scale becomes in both kinds of workpieces.

(a) (b)

Fig. 2. XRD result of punch surface for (a) S45C and (b) SUS310S workpieces.

(a) (b)

Fig. 3. SEM image of mill scale cross section (3 sec (contact time), 40 times (number of contacts) for (a) S45C and (b) SUS310S workpieces.
462 Nobuki Yukawa, EijiNobuki YukawaFujiwara/
Abe, Shohei et al. / Procedia
ProcediaManufacturing
Manufacturing1500
(2018) 59–64
(2018) 000–000

12

Thickness of mill scale/μm

10 Kind of strips contact time
3sec
8 S45C 4sec
5sec
6
3sec
4 SUS310S 4sec
5sec
2

0
0 10 20 30 40 50 60 70
Number of contacts

Fig. 4. Relation thickness of mill scale and contact number.

3. Determination of heat transfer coefficient

3.1. Experimental procedure

High speed steel SKH51 (JIS) is used for the punch and S45C (JIS) and SUS310S (JIS) are for the workpieces. The
punch is a cylindrical column, which dimensions are Φ24 mm in diameter and 17 mm in height. The workpiece is also
a cylindrical column, which dimensions are Φ27 mm in diameter and 20 mm in height.
Fig. 5 shows the schematic set-up of the experiment. The experimental procedure consists of 5 steps. First, the
experiment of generating a mill scale of hot rolling is done in same condition. Second, workpieces are heated at 1080
˚C and retained in an air atmosphere furnace for 10 min. Then the workpiece is taken out from the furnace and placed
on a die in 8 sec, and contacted to the punch at 50 MPa. In this experiment, the surface oxide scale on the workpiece
is not removed. Third, temperature change inside of the punch is measured by three K- type thermocouples with
stainless steel sheaths, inserted at 0.5, 1.0 and 1.5 mm from the bottom surface of the punch, as shown in Fig. 5(c).

Fig. 5. Experiment configuration; (a) photo of experiment; (b) schematic view of experiment configuration; (c) scope of punch.
 Nobuki Yukawa et al. / Procedia Manufacturing 15 (2018) 59–64 63
Author name / Procedia Manufacturing 00 (2018) 000–000 5

3.2. Analysis condition

Fitting curves for the heat transfer coefficient are obtained by finite element analysis, which was performed at
same condition of the contact experiment. We performed a trial and error procedure of the fitting experiment.
In the analysis, a series of calculations are done. First, cooling in the air for 4 sec., then cooling on the lower die
for 4 sec, and last, contact with the upper die for 30 sec. The heat transfer coefficients between the workpiece and air,
the workpiece and lower die are 0.1 and 0.5 kWm-2K-1, respectively. The heat transfer coefficient between the
workpiece and the upper die is varied from 3.0 to 8.0. An example of the measured temperature change (mill scale
formation conditions: workpiece S45C, contact time 5sec, number of contacts 24 times, heat transfer coefficient
measurement conditions: heating temperature of workpiece 1080 ˚C, heating time 10 min) and the calculated results
are shown in Fig. 6(a), (b). After calculation, heat transfer coefficient is determined as hc which gives the minimum
error between the calculated temperature by FEM and measured one. hc = 3.7 kWm-2K-1 is obtained in the case shown
in Fig. 5.

Generationg experiment condition 330

Contact time : 5 sec
Number of contact : 24 times

Temperarure of punch/ ºC
325
350
Temperarure of punch/ ºC

300 320
250 Experiment
200
hc=3.5 315
hc=3.6
150 310
hc=3.7
100
hc=3.8 305
50
hc=3.9
0 300
0 5 10 15 20 25 30 12 13 14 15
Contact time/s Contact time/s

Fig. 6. Punch temperature change and fitting curves.

3.3. Result and discussion

Fig. 7(a) shows the relation between the thickness of mill scale and the heat transfer coefficient. The heat transfer
coefficient decreases as the thickness of mill scale increases. It is considered that the mill scale has a lower heat
conductivity than that of steel, thus the heat transfer decrease.
Heat resistance between the workpiece and the punch is equal to the inverse number of heat transfer coefficient.
In the heat flow from the strip to the punch, total heat resistance is sum of each layer and each interface heat resistance.
Heat resistance is defined between the strip and the oxide scale on the strip: Rstrip-oxide scale, of the oxide scale layer:
Roxide scale, between the oxide scale on the strip and the mill scale: Rinterface, of the mill scale layer: Rmill scale , between
the mill scale and the punch: Rmill scale-punch. In this study, it is assumed that the thermal resistance Rstrip-oxide scale and Rmill
scale-punch is small enough compared to the others because it is formed in chemical reactions and these interfaces are
considered to be in close contact. Thus, we consider the heat resistance between workpiece and punch: R as follows.

𝑅𝑅𝑅𝑅 = 𝑅𝑅𝑅𝑅𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑜𝑜𝑜𝑜 + 𝑅𝑅𝑅𝑅𝑜𝑜𝑜𝑜𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑜𝑜𝑜𝑜𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 + 𝑅𝑅𝑅𝑅𝑚𝑚𝑚𝑚𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑜𝑜𝑜𝑜 , (1)

𝑅𝑅𝑅𝑅 = 1�ℎ . (2)

𝑠𝑠𝑠𝑠

Rinterface and Roxide scale are mainly affected by the heating time and the heating temperature. In this experiment, all
workpieces have the same heating condition. Thus, Rinterface and Roxide scale are constant and independent from the
thickness of the mill scale. Fig. 7(b) shows the relation between the thickness of mill scale and the heat resistance of
mill scale. It was found that the thicker mill scale is, the bigger heat resistance between the strip and the work roll is.
64 Nobuki Yukawa et al. / Procedia Manufacturing 15 (2018) 59–64
6 Nobuki Yukawa, Eiji Abe, Shohei Fujiwara/ Procedia Manufacturing 00 (2018) 000–000

8.0 0.08
7.5
0.07
Heat transfer coefficient/kWm⁻²K⁻¹

7.0

Heat resistance/kWm⁻²K⁻¹
0.06
6.5
6.0 0.05
5.5 0.04
5.0 0.03
4.5
0.02
4.0
0.01
3.5
3.0 0.00
0.0 2.0 4.0 6.0 8.0 10.0 12.0 0.0 2.0 4.0 6.0 8.0 10.0 12.0
Thickness of scale/μm Thickness of scale/μm
(a) (b)

Fig. 7. (a) Relationship between number of contacts and heat transfer and (b) relationship between thickness of mill scale and heat resistance.

4. Conclusion

In this study, a generating method of mill scale in a laboratory is developed. The heat transfer coefficients of mill
scale are measured, and the following results were obtained.
1. The oxide scale which contains Fe3O4 as main component was produced in uni-axis compression contact test.
Main component of oxide scale was Fe3O4 in both S45C and SUS310S workpieces.
2. The thickness of the mill scale with S45C workpiece was thicker than that of SUS310S workpiece.
3. The relation between the heat resistance of the mill scale and its thickness was obtained.

References

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Nippon Steel Technical report, 36-417 (2013) 1128.
[2] T. Tsuchihashi, J. Satoh, T. Shiraishi, K. Kawashima, K. Hirata, Y. Ooike, Application of high speed steel rolls to downstream stands in hot
finishing mill, CAMP-ISIJ, 9 (1996) 968.
[3] H. Okada, Deformation behavior of oxide scale in hot strip rolling, Nippon Steel & Sumitomo Metal Technical Report, 401 (2015) 75.
[4] K. Kusabiraki, T. Sugihara, T. Ooka, High temperature oxidation of Fe-Si alloys in Ar-H2O atmospheres, Journal of Tetsu-to-hagane, 77 (1991)
123.
[5] Y. Sekimoto, M. Tanaka, T. Yoshimura, Study on the formation of scale layer on work rolls in hot rolling, Journal of Tetsu-to-hagane, 20 (2008)
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