Assignment-1

Subject: MM 3203
NAME:
ROLL NO.:
1. A cylinder (ho = 3 cm, do = 1 cm) is compressed by an open die
forging process. The true strain to fracture for the cylinder is ɛ f =2 and
the governing deformation relationship is
σ t=4 5 0 ε
0. 4
MPa
The lubricant used provides a friction coefficient of 0.1. The process is
limited by either platen yielding or fracture. If the yield stress of the
platens is 800 MPa, do the platens yield or does the specimen fracture?
2. You are involved in the design of a large cold rolling mill. The
intended mill application is flat rolling of a 1045 steel strip of 1.5
m width, from 3 mm to 2.2 mm thickness in one pass. The roll
diameter is fixed at 0.25 m and the envisaged lubrication system
should result in a friction coefficient of 0.05.
(a) Calculate the roll separating force.
(b) If the intended strip exit speed is 4 m/s, what is the mill motor
power required for the 3 mm to 2.2mm thickness reduction? (Both
top and bottom rolls will be driven.)
(c) For this application do you recommend a two-high or four-high mill
configuration? State reasons for your answer.
3. The motors of a rolling mill are capable of producing 1000
horsepower (746 kW) when the work rolls are rotating at 100rpm.
The mill is to be used for cold rolling AA-1100 aluminium plate from
25 mm to 20 mm thickness. The mill has an efficient lubrication system
that effectively reduces the roll workpiece interface friction to low
values (therefore assume frictional effects are negligible). If the work
roll diameter is 60 cm, what is the maxi- mum width that can be
rolled at full power?
(b) Is the rolling deformation of the strip in part (a) homogeneous?
Briefly explain your answer.
3. The motors on a rolling mill are rated at 100 kW maximum power and
a maximum speed of 60 rpm. The maximum force that the rolling
mill can apply is 1000 kN. The roll-workpiece interface is lubricated
with mineral oil, giving a coefficient of friction of 0.1. The mill is
to be used to roll aluminium sheet with an initial thickness of 4
mm, a strength constant of 200 MPa and a strain hardening
coefficient of 0.18.
(a) From a simple geometrical analysis of the rolling geometry it can
be shown that
( ho−hi )max =μ2 R
where: R is the roll radius, μ is the friction coefficient h o is the
initial sheet thickness hi is the rolled thickness. With this information,
calculate the minimum thickness to which the sheet can be rolled.
(b) For the reduction calculated in part (a), if the motors are run at
100% power and speed, what is the maximum width of sheet that
can be rolled?