The 1974 Campbell Memorial Lecture

The American Society for Metals

Contributions to the Theory and

Practice of Cold Rolling

D O N A L D J. M c P H E R S O N

T h e d e v e l o p m e n t of a c o m p r e h e n s i v e c o m p u t e r i z e d m o d e l f o r c o l d r o l l i n g i s d e s c r i b e d .
R o l l i n g f o r c e s , t o r q u e s , f o r w a r d s l i p , t e m p e r a t u r e s of r o l l s a n d s t r i p , t h e r m a l c a m b e r s
of r o l l s , a s w e l l a s s t r i p t h i c k n e s s p r o f i l e a n d f l a t n e s s , a r e p r e d i c t e d . T h e m o d e l i s a p -
p l i c a b l e t o b o t h b a s i c a n d a p p l i e d s t u d i e s of t h e r o l l i n g p r o c e s s . Its p r i m a r y p u r p o s e s
a r e to a i d in o p t i m i z i n g p e r f o r m a n c e of e x i s t i n g m i l l s , in t h e d e s i g n of n e w c o l d m i l l s ,
a n d in d e v i s i n g o p e n - l o o p a n d c l o s e d - l o o p a u t o m a t i c f l a t n e s s - c o n t r o l s y s t e m s .

T H I S is the f o r t y - e i g h t h annual C a m p b e l l M e m o r i a l
L e c t u r e c o n v e n e d t o r e m e m b e r a n d h o n o r a m a n of i n -
d o m i t a b l e s p i r i t . F o r P r o f e s s o r C a m p b e l l , b l i n d e d in
a l a b o r a t o r y a c c i d e n t a t t h e a g e of 28, c o n t i n u i n g l i f e
w a s u n t h i n k a b l e w i t h o u t t h e c o n t i n u a n c e of p e r s o n a l
p r o d u c t i v i t y . And p r o d u c e he did, as a t t e s t e d by s c o r e s
of p i o n e e r i n g i n v e s t i g a t i o n s into the c o n s t i t u t i o n and
h e a t t r e a t m e n t of s t e e l , a n d m o r e i m p o r t a n t l y , b y h u n -
d r e d s of s t u d e n t s i n s p i r e d b y h i s e n t h u s i a s t i c e x a m p l e
t o t a k e t h e p a t h s of m e t a l l u r g i c a l p r o d u c t i v i t y .
I a m g r e a t l y h o n o r e d to b e a m o n g t h o s e who h a v e
b e e n g i v e n t h e o p p o r t u n i t y to t o a s t t h e m e m o r y of
E d w a r d D e M i l l e C a m p b e l l w i t h a p r o g r e s s r e p o r t in
t h e f i e l d of m e t a l l u r g y .
M o s t of t h e 47 p r e v i o u s C a m p b e l l l e c t u r e r s h a v e h a d
a n i n t i m a t e a s s o c i a t i o n w i t h a s p e c i f i c f i e l d of r e s e a r c h ,
u s u a l l y of d e c a d e s s t a n d i n g . S o m e d r i f t e d into b r o a d e r
a c t i v i t y with a little l e s s p e r s o n a l i n v o l v e m e n t at the
b e n c h o f s c i e n t i f i c i n q u i r y . A s o n e of t h o s e w h o s e d a i l y
w o r k in i n d u s t r i a l c o r p o r a t e m a n a g e m e n t i s s c a r c e l y
the yarn from which Campbell lectures are woven, I
s h a l l r e p o r t to you on t h e p r o g r e s s of a m a j o r p r o g r a m
i n v o l v i n g a t a l e n t e d a n d d e d i c a t e d g r o u p of K a i s e r A l u -
minum and Chemical Corporation researchers, to whom

search Institute) in 1950. His experienceincludesa strongbackground in active

DONALDJ. McPHERSON,formerTrustee(1970-72) of the AmericanSociety
for Metals,is Vice Presidentand Directorof Technologyfor KaiserAluminum&
Chemical Cow., Oakland, Calif.
Formerly VicePresidentof the liT ResearchInstitute, Dr. McPhersonhas had
full responsibilityfor KaiserAluminum& ChemicalCorporation'stechnological
research and developmentprogram sincejoining the companyin 1969.
A native of Columbus, Ohio, Dr. McPhersonholds the Bachelor of Metallurgical
Engineeringand Masterof SciencedegreesfromOhio State University.He received
his doctorate at OSU in 1949.
He has servedin various researchand technicalposts with Battelle Memorial
Institute, Carnegie-IllinoisSteelCorp., OSU ResearchFoundation, and Argonne
National Laboratory, beforejoining Armour ResearchFoundation (now IIT Re-
research-he has publishedover 30 technicalpapers-prior to assumingincreasing
responsibilityfor researchadministration.At IITRI he movedfrom Research
Metallurgist to Director of Metals Research,and finally to Vice Presidentin
charge of researchin metallurgy,ceramics,chemistry,life sciences,and the
mechanicsof materials.
Dr. McPhersonhas servedon a number of governmentalcommittees,including
the MaterialsAdvisoryBoard of the National Academyof Sciencesand the Na-
tional AdvisoryCommitteefor Aeronautics.He is a memberof AmericanSociety
for Metals,AmericanInstitute of Mining,Metallurgicaland Petroleum Engineers,
AmericanCeramic Society, the MaterialsDivisionof AmericanInstitute of Chemi-
cal Engineers,AmericanSociety for Testing and Materials,and AmericanAssocia-
tion for the Advancementof Science.

METALLURGICAL TRANSACTIONS VOLUME 5, DECEMBER 1974-2479

all c r e d i t is due. The l e c t u r e will c e n t e r on t h e i r d e -
v e l o p m e n t of a model, u s i n g c o m p u t e r solution t e c h -
n i q u e s , which a c c u r a t e l y d e s c r i b e s the cold r o l l i n g
p r o c e s s for a l u m i n u m - - a model which we b e l i e v e will
make a c o n t r i b u t i o n to g e n e r a l r o l l i n g t h e o r y for a l l
metals.
THE COLD ROLLING PROCESS
AND EQUIPMENT
R o l l i n g is u n q u e s t i o n a b l y one of the m o s t i m p o r t a n t
m e t a l f o r m i n g p r o c e s s e s we use today. In 1973, 92 pct
of the a l u m i n u m , s t e e l and copper produced in the
world was r o l l e d , a total of 728 m i l l i o n tons* of m e t a l .
*Englishunitsof measurewillbe used throughout,sincethe computational
program is adapted to currentU,S,industrypractice. Factorsfor conversionto
S.I. unitsare appended.
D u r i n g the hour of this l e c t u r e you m a y expect that 85
t h o u s a n d tons of m e t a l will have been r o l l e d !
Over the past 40 y e a r s , the cold r o l l i n g p r o c e s s to
p r o d u c e sheet has p r o g r e s s e d f r o m two-high hand
m i l l s , t a k i n g a v e r y l a r g e n u m b e r of s m a l l r e d u c t i o n s
and p r o d u c i n g v e r y unflat sheet at a low yield, to highly
p r o d u c t i v e m u l t i s t a n d , or t a n d e m , f o u r - h i g h m i l l s .
T h e s e c o m m e n c e with l a r g e h o t - b a n d coils, take l a r g e
t h i c k n e s s r e d u c t i o n s at high speed, and produce f i n -
ished coil with c o m p a r a t i v e l y good f l a t n e s s and t h i c k -
ness tolerance.
A r o l l i n g m i l l weighs m a n y tons and yet m u s t p r o -
duce cold r o l l e d s t r i p to t o l e r a n c e s m e a s u r e d in t e n -
thousandths of an inch. In t a n d e m m i l l s the s t r i p can
be r e d u c e d in all s t a n d s p r o g r e s s i v e l y and s i m u l t a n e -
ously. Cost and quality c o m p e t i t i o n in the i n d u s t r y
have led to the adoption of new technology f r o m the
fields of m e c h a n i c a l e n g i n e e r i n g , h y d r a u l i c s and e l e c -
t r o n i c s in m i l l d e s i g n and o p e r a t i o n as r a p i d l y as it
could be a s s i m i l a t e d . In g e n e r a l , the t h r u s t of d e v e l -
opment has b e e n toward higher p r o d u c t i v i t y and toward
m e c h a n i s m s for m o r e p r e c i s e c o n t r o l of finished s t r i p
gage.
Fig. 1 i n d i c a t e s the b a s i c c o n t r o l s a v a i l a b l e to a m i l l
o p e r a t o r . The s t r i p is r e d u c e d b e t w e e n two work r o l l s
supported by two backup r o l l s . The s m a l l e r d i a m e t e r
J- - Deflector
Work Roll
-- Jack
l4 Spray Co .fling Zones ]J ~ . . . , * - Backup Roll
[ ~ Jack
E
[
Fig. i--Four-high mill stand and controls.
2480-VOLUME 5, DECEMBER 1974
work r o l l s r e d u c e f o r c e and e n e r g y to c a u s e d e f o r m a -
tion, while the l a r g e r backup r o l l s d e c r e a s e m e c h a n i -
cal d e f l e c t i o n s . The necks of the r o l l s fit into b e a r -
ings and b e a r i n g chocks which a r e s u p p o r t e d in two
m i l l f r a m e s . Large s c r e w s at the top of the f r a m e
r a i s e and lower the stop p o s i t i o n of the top backup
chock which in t u r n d e t e r m i n e s the n o m i n a l gap b e -
tween the work r o l l s . The work r o l l s a r e d r i v e n b y dc
m o t o r s through a g e a r r e d u c e r and pinion stand to p r o -
vide i n s t a n t l y v a r i a b l e speed and torque.
In r e l a t i v e l y r e c e n t t i m e s , m i l l s t a n d s have b e e n
equipped with h y d r a u l i c c y l i n d e r s , u s u a l l y c a l l e d work
r o l l j a c k s , which m a y be used to push the ends of the
work r o l l s a p a r t to aid in a l l e v i a t i n g edge wave u n f l a t -
n e s s of the s t r i p . Other h y d r a u l i c c y l i n d e r s , c a l l e d
deflector j a c k s , a r e placed b e t w e e n the work r o l l and
backup r o l l chocks so that the ends of the work r o l l s
m a y be forced t o g e t h e r . This will c o u n t e r a c t any t e n -
dency of the s t r i p to f o r m c e n t e r b u c k l e s . Some m i l l s
also have l a r g e d i a m e t e r s h o r t - s t r o k e h y d r a u l i c c y -
l i n d e r s b e t w e e n top and bottom backup r o l l chocks to
cause backup r o l l b e n d i n g for s t i l l f u r t h e r c o n t r o l of
buckles.
The work r o l l s a r e cooled with s p r a y s that a r e d i s -
t r i b u t e d a c r o s s the width, with individual c o n t r o l s to
a d j u s t local cooling r a t e s and t h e r m a l c a m b e r . The
s t r i p payoff and takeup r e e l s a r e g e n e r a l l y of the e x -
panding a r b o r type with m o t o r b r a k e and drive, r e -
s p e c t i v e l y , to p r o v i d e b a c k w a r d and f o r w a r d t e n s i o n
to the s t r i p .
Thus, a m i l l o p e r a t o r can c o n t r o l the speed, f o r w a r d
and b a c k w a r d t e n s i o n , the r o l l gap, r o l l bending, and
work r o l l cooling.
Exit t h i c k n e s s of s t r i p g e n e r a l l y has b e e n m o n i t o r e d
by contact m i c r o m e t e r s , although t h e s e a r e b e i n g
s u p e r s e d e d by r a d i a t i o n gages and other t h i c k n e s s
s e n s o r s . Many m i l l s a r e b e i n g equipped with c o m p u t -
e r s for the a u t o m a t i c c o n t r o l of exit gage. Signals
f r o m the s e n s o r s a r e used by the c o m p u t e r to c a l c u -
late the changes in r o l l gap or t e n s i o n and r o l l v e l o c -
ity r e q u i r e d to c o n t r o l s t r i p t h i c k n e s s within n a r r o w
l i m i t s . However, m o s t of the c o m p u t e r s y s t e m s c o n -
t r o l gage only along a single t r a c k s o m e w h e r e a c r o s s
the width where a t h i c k n e s s s e n s o r is located. T h i c k -
n e s s v a r i a t i o n s a c r o s s the width a r e n o r m a l l y i g n o r e d
by p r e s e n t a u t o m a t i c gage c o n t r o l s y s t e m s .
While the a d v a n c e s in p r o d u c t i o n r o l l i n g over s e v -
e r a l d e c a d e s have b e e n r e m a r k a b l e , the m a j o r u n -
solved p r o b l e m today is how to p r o d u c e s t r i p that is
t r u l y flat. Cold s t r i p will tend to buckle if the p e r c e n -
tage r e d u c t i o n (or elongation) v a r i e s a c r o s s the width. 1-s
This m e a n s that if flat s t r i p is to be r o l l e d , the r o l l gap
d i m e n s i o n s m u s t be m a i n t a i n e d a c r o s s the width d u r i n g
each r o l l i n g p a s s to m a t c h the exact profile of the i n -
c o m i n g hot m i l l s t r i p , on a r e l a t i v e p e r c e n t a g e b a s i s .
After r o l l i n g , cold m i l l p r o d u c t m a y be i m p r o v e d in
f l a t n e s s by r o l l e r or s t r e t c h e r l e v e l l i n g . T h e s e o p e r -
ations r e p r e s e n t additional p r o c e s s i n g c o s t s to a c h i e v e
a p r i m e product. The p r o b l e m , then, is to gain suffi-
c i e n t u n d e r s t a n d i n g of the cold r o l l i n g p r o c e s s to p e r -
m i t p r o d u c t i o n of d i r e c t l y s a l e a b l e , p e r f e c t l y flat p r o d -
uct off the m i l l s . It is a v e r y c o m p l e x task to p r e d i c t
t h i c k n e s s v a r i a t i o n s a c r o s s the width of s t r i p , i n c l u d -
ing the a s s o c i a t e d defect of b u c k l e s . Depending upon
the m e c h a n i c a l or t h e r m a l a b e r r a t i o n s which c a u s e
METALLURGICALTRANSACTIONS
 BASICDATA MATH MODELS INPUT VARIABLES
I O __
O
o Mill D~mensions
<:3 Reduction
Speed
O Strip Width
Gauge
O Alloy
Lubricant
Cenier Edge Quarter Tension

Fig. 2--Common buckle types.

Mill Dimensions
the resulting stress distributions, these defects may
Coolant Pressure
Coolant Pattern
t a k e the f o r m of c e n t e r , edge o r q u a r t e r b u c k l e s (Fig. Spray Array
2). C o m p a r e d to a u t o m a t i c gage c o n t r o l , a u t o m a t i c
b u c k l e c o n t r o l is s t i l l in i t s infancy. However, much
e f f o r t is b e i n g devoted to t h i s p r o b l e m , and A S E A -
ALCAN 4 have r e p o r t e d s i g n i f i c a n t p r o g r e s s .
~ o l l Temps.v~
PROGRAM OBJECTIVES
~Camber~ ~ ~idth & Time~/
I
Four years ago, the mill products division and man- Flow Stress / Roll Gap and Mill Dimensions
agement of my company acknowledged that we re- Coef. F r i c t i o n [ ~ l StrlpShape I I BuR Grind Shape
mained essentially dependent upon highly skilled ar- WR Grind Shape
tisans for the production volume, yield and quality of Initial Strip Shape
a major product line. However, the constantly increas- rVrofile of Cross h II
Strip y
and Flatness
BUR Bending
ing demand for improvement in all of these factors WR Bending
called for a higher degree of technical sophistication
than the rollers had available. Simultaneously, rolling
t
theory and modeling, equipment and controls, and Rolled Strip
computational power were advancing steadily. A cor-
porate decision was made to mount an effort directed Fig. 3--Flow chart of rolling model.
toward the maximum utilization of the science of roll-
ing, which would be fully coordinated with actual mill t a t i o n s in c o m p u t a t i o n a l p o w e r . Some r e c e n t w o r k b y
problems throughout the company. A new department was Koot s and B r y a n t 7 a r e good e x a m p l e s of l a r g e r e f f o r t s
created at our Center for Technology, with personnel to c o m b i n e the i n t e r d e p e n d e n t f a c t o r s .
drawn from many departments to provide the necessary Our t a s k was to p r o d u c e a m o d e l whose p r e d i c t i o n s
broad range of disciplines. would c o r r e l a t e a c c u r a t e l y with m i l l r e s u l t s on a l u -
The ambitious overall goal was to use rolling theory m i n u m a l l o y s . This involved s e l e c t i v e l y t e s t i n g e x -
to develop computer-stored hot and cold rolling mod- i s t i n g math m o d e l s and d e v e l o p i n g i m p r o v e m e n t s to
els, which would provide the operating parameters give a c o m p r e h e n s i v e cold r o l l i n g m o d e l .
necessary for any of our mills to produce flat strip
with m i n i m u m v a r i a t i o n in gage o v e r length and width.
R e s u l t s which can be put to i m m e d i a t e use a r e a COLD ROLLING MODEL
g r e a t e n c o u r a g e m e n t to i n d u s t r i a l m a n a g e m e n t in c o n - In the following discussion of the development and
tinuing s u p p o r t of so l a r g e an R&D effort. E a r l y g o a l s application of the cold rolling model, I shall present,
thus included a i d i n g the m i l l s in u t i l i z i n g a l l of t h e i r in s e q u e n c e :
available horsepower and/or speed, providing infor- 1. A flow c h a r t of the o v e r a l l m o d e l , including its
m a t i o n for the d e s i g n of a u t o m a t i c gage and f l a t n e s s four b a s i c m o d e l e l e m e n t s , b a s i c input data, v a r i a b l e
c o n t r o l s y s t e m s , and defining the d e s i g n c r i t e r i a for o p e r a t i n g inputs, and the d a t a output. The i m p o r t a n c e
a n e x t - g e n e r a t i o n cold m i l l . of e a c h b a s i c m o d e l will b e s u m m a r i z e d .
We have c o m p l e t e d M a r k I of the m o d e l i n g w o r k for 2. A d e t a i l e d d i s c u s s i o n of the four b a s i c m o d e l s
cold r o l l i n g , which I s h a l l c o v e r h e r e . The hot r o l l i n g and t h e i r d e v e l o p m e n t , a c c o u n t i n g for a l l of the p a -
m o d e l w o r k is in p r o g r e s s and n e a r i n g c o m p l e t i o n . r a m e t e r s involved, but s p a r i n g the e x t r e m e l y c o m p l e x
R o l l i n g t h e o r y o r s e g m e n t s of r e s e a r c h p e r t i n e n t to m a t h e m a t i c a l t r e a t m e n t s which w e r e n e c e s s a r y . This
it, c o m m e n c i n g about 30 y e a r s ago with Orowan, s have will b e confined to what o c c u r s at a s i n g l e m i l l stand.
t e n d e d to r e f l e c t the i n t e r e s t o r b a c k g r o u n d of the i n - 3. A d i s c u s s i o n of how the b a s i c m o d e l s a r e c o m -
v e s t i g a t o r (e. g . , m a t h e m a t i c i a n , m e c h a n i c a l e n g i n e e r , b i n e d to s o l v e m i l l p r o b l e m s , i n t r o d u c i n g m u l t i s t a n d
m e t a l l u r g i s t , m i l l d e s i g n e r ) o r the p a r t i c u l a r p r o b l e m p r o g r a m s and a d e s c r i p t i o n of the m a s t e r c o m p u t e r
to be s o l v e d (e.g., s t r i p defect, r o l l b r e a k a g e , gage p r o g r a m and d a t a b a s e s t o r a g e that a r e u t i l i z e d .
c o n t r o l , m i l l cooling, l u b r i c a t i o n d e v e l o p m e n t ) . Due 4. An e x a m p l e of using the cold r o l l i n g c o m p u t e r
to the i n c r e d i b l y c o m p l e x a r r a y of i n t e r d e p e n d e n t m e - m o d e l to a n a l y z e a p a r t i c u l a r o p e r a t i n g p r o b l e m f o r
c h a n i c a l and t h e r m a l p a r a m e t e r s , the o v e r a l l p r o b l e m a f i v e - s t a n d t a n d e m m i l l , d i s p l a y i n g the i m p o r t a n t
h a s tended to be a d d r e s s e d b y s u b - p r o b l e m s o r with d a t a output.
o v e r s i m p l i f i e d a s s u m p t i o n s which e a s e d e a r l i e r l i m i - 5. E x a m p l e s of v e r i f i c a t i o n of the m o d e l ' s p r e d i c -

METALLURGICAL TRANSACTIONS VOLUME 5, DECEMBER 1974-2481

t i v e a c c u r a c y with a c t u a l r o l l i n g m i l l data.
A s i m p l i f i e d flow c h a r t of the r o l l i n g m o d e l is shown
in Fig. 3. The four b a s i c m a t h e m a t i c a l m o d e l s a r e :
F o r c e - T o r q u e - S l i p , E n e r g y B a l a n c e , Roll T h e r m a l
C a m b e r , and Roll Gap and S t r i p Shape. Oval b l o c k s
d e s i g n a t e i n d i v i d u a l o r c o m b i n e d m o d e l outputs. The
final outputs of the c o m b i n e d m o d e l a r e T h i c k n e s s
C r o s s P r o f i l e and F l a t n e s s of R o l l e d S t r i p . The b a s i c
d a t a l i s t e d on the left s i d e of the flow c h a r t a r e r e -
q u i r e d in o r d e r f o r the m o d e l s to p r e d i c t a c c u r a t e l y .
A m a j o r p a r t of the p r o g r a m e f f o r t was expended in
o b t a i n i n g the n e c e s s a r y b a s i c d a t a in l a b o r a t o r y and
plant experimentation.
The c o n t r o l l a b l e o p e r a t i n g v a r i a b l e s that affect the
o u t c o m e a r e l i s t e d on the r i g h t . With the m o d e l it is
p o s s i b l e to d e t e r m i n e the independent e f f e c t s of each
of t h e s e v a r i a b l e s on s t r i p f l a t n e s s . This is n e a r l y
i m p o s s i b l e in a c t u a l r o l l i n g e x p e r i m e n t s w h e r e only
c o m b i n e d e f f e c t s a r e d i s c e r n i b l e . The model, in fact,
i s u s e d a s an e x p e r i m e n t a l r o l l i n g m i l l . It a l l o w s one
to t r y d i f f e r e n t m e c h a n i c a l s h a p e s of w o r k r o l l s and
b a c k u p r o l l s , c o o l a n t a p p l i c a t i o n t e c h n i q u e s , and o t h e r
v a r i a b l e s , at much l o w e r c o s t and r i s k than on an a c t u a l
m i l l . The m o d e l r e s u l t s a r e e a s i l y i n t e r p r e t e d in
t e r m s of r e l a t i v e e f f e c t s of e a c h v a r i a b l e . P l a n t t r i a l s ,
of c o u r s e , a r e s t i l l n e e d e d to c o n f i r m m o d e l p r e d i c -
tions.
B e f o r e p r o c e e d i n g to a m o r e d e t a i l e d d e s c r i p t i o n of
the four b a s i c m o d e l s , l e t m e give a b r i e f s u m m a r y
of t h e m .
The F o r c e - T o r q u e - S l i p Model p r e d i c t s the f o r c e
n o r m a l to the p l a n e of the s h e e t b e i n g r o l l e d , the
t o r q u e r e q u i r e d to t u r n the r o l l s , and the f o r w a r d s l i p .
F i g . 4 shows what t h e s e t e r m s mean. Bite i s the t e r m
u s e d for the length of a c t u a l c o n t a c t b e t w e e n s t r i p and
r o l l s . Since m a s s flow is c o n s t a n t , the s t r i p a c c e l e r -
a t e s t h r o u g h the b i t e a s it is r e d u c e d in t h i c k n e s s , and
thus e x i t s at a h i g h e r v e l o c i t y than that at e n t r y . The
r o l l s n o r m a l l y t u r n with a p e r i p h e r a l s p e e d b e t w e e n
the s t r i p e n t r y and exit s p e e d s . The p l a n e in the b i t e
w h e r e the s p e e d of the p a r t l y r e d u c e d s t r i p is i d e n t i c a l
to the r o l l p e r i p h e r a l s p e e d is c a l l e d the n e u t r a l plane.
The l o c a t i o n of the n e u t r a l p l a n e is a function of e n t r y
and exit t e n s i o n l e v e l s , f r i c t i o n c o n d i t i o n s , r e d u c t i o n ,
and s p e e d . F o r w a r d s l i p is defined a s the p e r c e n t a g e
i n c r e a s e of s t r i p exit s p e e d o v e r r o l l s p e e d .
Knowledge of f o r c e , t o r q u e , and s l i p a l o n e i s i n s u f -
f i c i e n t to c a l c u l a t e s t r i p f l a t n e s s . Nonuniform exit t e n -
s i o n i n d i c a t e s t h a t unflat s t r i p is b e i n g r o l l e d , and
f o r c e , t o r q u e , and s l i p will t e n d to v a r y a c r o s s the
width. Many i t e r a t i o n s thus b e c o m e involved in d e t e r -
m i n i n g the t e n s i o n and f o r c e v a r i a t i o n s a c r o s s the
width, a s will be e l a b o r a t e d l a t e r . The i n i t i a l c a l c u l a -
tion s t e p s a s s u m e u n i f o r m f o r c e and t o r q u e conditions
so t h a t an e n e r g y b a l a n c e can b e m a d e .
The E n e r g y B a l a n c e Model is d e s i g n e d to d e t e r m i n e
the d i v i s i o n of r o l l i n g e n e r g y that flows a s h e a t to the
r o l l s and to the s t r i p ; m a s s and e n e r g y b a l a n c e s ; and
n o m i n a l r o l l and s t r i p t e m p e r a t u r e s . The e f f e c t s of
s t r i p quenching which r e s u l t f r o m r o l l coolant f a l l i n g
onto the s t r i p o r f r o m d i r e c t s t r i p s p r a y s a r e included.
If one knows the h e a t flow to the r o l l s and s t r i p a s a
function of r o l l and s t r i p t e m p e r a t u r e s e n t e r i n g the
b i t e , it is p o s s i b l e to c a l c u l a t e the t h e r m a l c a m b e r o r
d i f f e r e n t i a l e x p a n s i o n of the w o r k r o l l .
2482-VOLUME 5, DECEMBER 1974
~rque~k o0,\ /o,,
Entr~trip I ~ vs
Tension-~ .........../"~l'~leutr~'
i -- -- ( Tension
/ I ('~'riPSpeed= VR)
/
\ Where: VR = Roll Peripheral Speed /
Vs = Exit Strip Speed
Fig. 4--Rollbite diagram.
The Roll T h e r m a l C a m b e r Model is the f i r s t that is
c o n c e r n e d with v a r i a t i o n s of conditions a c r o s s the
width. The m a i n p r o b l e m is that the c e n t r a l r e g i o n s
of the w o r k r o l l s a r e b e i n g h e a t e d w h e r e t h e y a r e in
contact with the s t r i p , but c o o l i n g is o c c u r r i n g o v e r
the e n t i r e r o l l width. The ends of the w o r k r o l l s b e -
yond the s t r i p edge a r e a l w a y s cooled, i n t e n t i o n a l l y
o r unintentionally, which c a u s e s the m i d d l e to r u n
w a r m e r than the ends. Due to a x i a l conduction, the
p o r t i o n of the r o l l j u s t i n s i d e the s t r i p edge r u n s
c o o l e r than the r o l l m i d d l e . A t h e r m a l c a m b e r thus
d e v e l o p s on the w o r k r o l l s within the r e g i o n in c o n -
t a c t with the s t r i p ; if not p r o p e r l y c o n t r o l l e d , it can
c a u s e s e v e r e s t r i p b u c k l e s . The t h e r m a l c a m b e r
a d d e d to the o r i g i n a l m e c h a n i c a l s h a p e of the w o r k
r o i l s m u s t be e x a c t l y equal and o p p o s i t e to the m e -
c h a n i c a l d e f l e c t i o n s to m a i n t a i n a r e c t a n g u l a r r o l l gap
s h a p e . To r o l l f l a t s t r i p , the r o l l gap s h a p e m u s t be
c o m p a t i b l e with the p r o f i l e of the h o t - m i l l p r o d u c t
e n t e r i n g the cold m i l l .
The Roll Gap and S t r i p Shape Model u s e s the output
of the Roll Thermal Camber Model and calculates, by
iteration, the mechanical deflections of the work rolls
and backup rolls. Strip tension is allowed to vary
across the width as dictated by the differential reduc-
tions, incoming strip profile, and resultant differential
strains. The Force-Torque-Slip Model is solved sepa-
rately for each increment of width in an iterative
scheme until necessary convergence criteria are met.
Input variables include mechanical grind shapes of the
work roll and backup roll, bending jack pressures, and
initial strip shape and flatness. Whilethe output of
primary interest is strip flatness, strip tension and
METALLURGICAL TRANSACTIONS
cross-thickness profiles are also available since these
m u s t be c o m p u t e d in o r d e r to obtain f l a t n e s s p r e d i c -
t i o n s . The Roll Gap and S t r i p Shape Model a l s o p r i n t s
out d e f l e c t i o n s due to bending, s h e a r , P o i s s o n ' s r a t i o ,
and r o l l f l a t t e n i n g .
S e v e r a l options a r e a v a i l a b l e in u s i n g the m o d e l s .
They involve s p e c i f y i n g d e s i r e d s t r i p s h a p e and f l a t -
n e s s and w o r k i n g b a c k w a r d s t o w a r d r e q u i r e d r o l l j a c k
pressures, mechanical grind shapes, or thermal cam-
b e r s . The m o d e l is p r o g r a m m e d in F o r t r a n V, and the
c o m p u t e r u s e d is an o f f - s i t e UNIVAC 1108. The 1108
is a c c e s s e d with an i n - h o u s e c o m p u t e r having a r e m o t e
job e n t r y s y s t e m which i n c l u d e s c a r d r e a d i n g , line
p r i n t i n g , and plotting.
DESCRIPTION O F MODELS
F o r c e - T o r q u e - S l i p Model
As s t a t e d e a r l i e r , it is not m y p u r p o s e to s u b j e c t
you to the e x t e n s i v e m a t h e m a t i c a l r e p r e s e n t a t i o n s of
the v a r i o u s m o d e l s , although t h e s e have b e e n r i g o r -
o u s l y d e v e l o p e d . I a n t i c i p a t e that full m a t h e m a t i c a l
t r e a t m e n t of the m o d e l s and t h e i r v e r i f i c a t i o n will be
p u b l i s h e d s u b s e q u e n t l y b y the r e s p o n s i b l e m e m b e r s
of our p r o j e c t t e a m . However, I would l i k e to i m p a r t
an a p p r e c i a t i o n of the p a r a m e t e r s which the F o r c e -
T o r q u e - S l i p Model m u s t t r e a t and t h e i r i n t e r a c t i o n s .
Alloy Condition: The flow s t r e s s , o r r e s i s t a n c e to
d e f o r m a t i o n , v a r i e s with a l l o y c o m p o s i t i o n . C o n s e -
quently, s p e c i f i c f o r c e is a function of the a l l o y b e i n g
r o l l e d . The a l l o y may, o r m a y not, have a d e g r e e of
p r i o r cold w o r k which a l s o a f f e c t s s p e c i f i c f o r c e . S u r -
f a c e t e x t u r e m a y a l s o v a r y with a l l o y a n d / o r p r i o r w o r k
and thus a f f e c t s the f r i c t i o n c h a r a c t e r i s t i c s d u r i n g r o l l -
ing.
Entry Strip Thickness: F o r a given p e r c e n t r e d u c -
tion, b i t e length i n c r e a s e s a s e n t r y s t r i p t h i c k n e s s i n -
c r e a s e s . Specific f o r c e i n c r e a s e s b e c a u s e of i n c r e a s e d
c o n t a c t length. In addition, the ' angle b e t w e e n s t r i p and
r o l l s u r f a c e s at the point of e n t r y i n c r e a s e s a s s t r i p
t h i c k n e s s i n c r e a s e s , a f f e c t i n g the amount of l u b r i c a n t
d r a g g e d into the b i t e and t h e r e f o r e the c o e f f i c i e n t of
friction during rolling.
Work Roll Diameter: Bite length i n c r e a s e s a s r o l l
d i a m e t e r i n c r e a s e s , and t h e r e f o r e s p e c i f i c f o r c e is
l a r g e r . On the o t h e r hand, angle of c o n t a c t d e c r e a s e s ,
with a c o n c o m i t a n t effect upon l u b r i c a n t e n t r y and c o -
e f f i c i e n t of f r i c t i o n .
Pass Reduction: The a m o u n t of r e d u c t i o n d u r i n g a
p a s s a f f e c t s the a m o u n t of s t r a i n h a r d e n i n g of the s t r i p ,
and thus a f f e c t s a v e r a g e flow s t r e s s and s p e c i f i c f o r c e .
Bite length, and t h e r e f o r e s p e c i f i c f o r c e , i n c r e a s e s with
increasing reduction. More reduction also creates more
wedge a c t i o n and, thus, m o r e t o r q u e . Reduction a l s o a f -
f e c t s the c o e f f i c i e n t of f r i c t i o n within the r o l l b i t e due
to change of d i f f e r e n t i a l s p e e d b e t w e e n r o l l and s t r i p
s u r f a c e s and the e f f e c t s of t e m p e r a t u r e and p r e s s u r e
on the v i s c o s i t y of the l u b r i c a n t f i l m .
Rolling Lubricant: D i f f e r e n t r o l l i n g l u b r i c a n t s have
d i f f e r e n t c o e f f i c i e n t s of f r i c t i o n and d i f f e r e n t r e -
s p o n s e s to s p e e d and p r e s s u r e . With o t h e r f a c t o r s
c o n s t a n t , an i n c r e a s e in the c o e f f i c i e n t of f r i c t i o n
m e a n s that a s m a l l e r c o n t a c t a r e a a h e a d of the n e u t r a l
plane is r e q u i r e d to i m p a r t the r e q u i r e d f o r w a r d t h r u s t
to the s t r i p ; c o n s e q u e n t l y the n e u t r a l p l a n e s h i f t s tO-
METALLURGICAL TRANSACTIONS
w a r d e n t r y . With a d e c r e a s e in c o e f f i c i e n t of f r i c t i o n ,
an o p p o s i t e shift o c c u r s . F o r w a r d s l i p is t h e r e f o r e
d i r e c t l y a f f e c t e d b y c o e f f i c i e n t of f r i c t i o n . When o t h e r
conditions a r e unchanged, p e a k p r e s s u r e i n c r e a s e s
with i n c r e a s i n g c o e f f i c i e n t of f r i c t i o n . Thus, c o e f f i -
cient of f r i c t i o n a l s o d i r e c t l y a f f e c t s s p e c i f i c f o r c e .
Roll Speed: The s p e e d of r o l l i n g a f f e c t s the amount
of l u b r i c a n t b e i n g d r a g g e d into the r o l l b i t e . T h i c k e r
l u b r i c a n t f i l m and l o w e r c o e f f i c i e n t of f r i c t i o n e x i s t
in the r o l l b i t e at h i g h e r s p e e d s . Roll s p e e d t h e r e f o r e
d i r e c t l y a f f e c t s s p e c i f i c f o r c e and f o r w a r d slip.
Front and Back Tensile Stresses: The t h e o r y of p l a s -
t i c i t y c o n f i r m s that r e s i s t a n c e to c o m p r e s s i v e d e f o r -
mation, o r flow s t r e s s , of m e t a l s is r e d u c e d when t e n -
s i l e s t r e s s is a p p l i e d in a d i r e c t i o n p e r p e n d i c u l a r to
the d i r e c t i o n of p r e s s u r e a p p l i c a t i o n . Consequently,
the a p p l i c a t i o n of s t r i p t e n s i o n can r e d u c e the f o r c e
r e q u i r e m e n t in r o l l i n g . If f r o n t t e n s i o n is changed
while o t h e r c o n d i t i o n s r e m a i n constant, r e s t o r a t i o n of
e q u i l i b r i u m of f o r c e s d i c t a t e s a shift in the n e u t r a l
p l a n e to effect a c o r r e s p o n d i n g change in net f r i c t i o n
f o r c e . The s a m e a r g u m e n t a p p l i e s to s t r i p b a c k t e n -
sion. A c c o r d i n g l y , s t r i p t e n s i o n s d i r e c t l y affect f o r -
w a r d s l i p . The d i f f e r e n c e in s t r i p f r o n t and b a c k t e n -
s i o n s a c t s a s a t o r q u e - c r e a t i n g f o r c e with r e s p e c t to
r o l I a x e s and so d i r e c t l y a f f e c t s s p e c i f i c t o r q u e .
All of the above f a c t o r s can b e r e d u c e d to m a t h e m a t -
i c a l r e l a t i o n s h i p s which f o r m the b a s i s of the F o r c e -
T o r q u e - S l i p - Model.
Initial d e v e l o p m e n t w o r k on t h i s m o d e l was done
under a c o n t r a c t with U.S. Steel E n g i n e e r s and C o n -
s u l t a n t s and u t i l i z e d i n s t r u m e n t e d r o l l i n g m i l l s at the
M o n r o e v i l l e r e s e a r c h l a b o r a t o r i e s of the United S t a t e s
Steel C o r p o r a t i o n . The c o n t r a c t o r s u p p l i e d e x p e r i m e n -
t a l r o l l i n g d a t a f o r t h r e e a l u m i n u m a l l o y s and a n a l y z e d
the r e s u l t s in t e r m s of W. L. R o b e r t s ' s i m p l i f i e d c o l d
r o l l i n g m o d e l f o r s t e e l 8-1~ a d a p t e d to a l u m i n u m (unpub-
l i s h e d ) . A c c e s s to t h i s e x p e r t i s e was h i g h l y b e n e f i c i a l
in getting our p r o g r a m under way.
While the s i m p l i f i e d m o d e l was s u f f i c i e n t l y a c c u r a t e
for m a n y a p p l i c a t i o n s , g r e a t e r a c c u r a c y was n e e d e d to
show e f f e c t s of s p e e d on f o r c e , t o r q u e , and f o r w a r d
s l i p . In addition, the t h e r m a l h e a t p a r t i t i o n a n a l y s i s
r e q u i r e d inputs of d i s t r i b u t i o n of f r i c t i o n and d e f o r m a -
tion e n e r g y t h r o u g h o u t the length of the b i t e . It b e c a m e
a p p a r e n t that no s i m p l i f i e d m o d e l could p r o v i d e the d e -
s i r e d a c c u r a c y for the r a n g e of c o n d i t i o n s and p a r a m -
e t e r s under c o n s i d e r a t i o n . M o r e f u n d a m e n t a l m o d e l s
a v a i l a b l e in the l i t e r a t u r e w e r e studied, but none m e t
our p a r t i c u l a r n e e d s o r was s u f f i c i e n t l y d o c u m e n t e d
for i m m e d i a t e u s e . S'11-23 Consequently, it was d e c i d e d
to develop a n o t h e r m o d e l u s i n g b a s i c p r i n c i p l e s of m e -
c h a n i c s , a p p r o a c h e s in the l i t e r a t u r e which a p p e a r e d
m o s t s u i t a b l e , and c o m p u t e r s o l u t i o n t e c h n i q u e s . T h i s
w o r k was p e r f o r m e d b y Dr. Yu-Wen Hsu of the K a i s e r
r e s e a r c h staff. M a j o r f e a t u r e s of the Hsu F o r c e -
T o r q u e - S l i p Model a r e a s follows:
1. The s o l u t i o n b e g i n s with a d i f f e r e n t i a l equation of
e q u i l i b r i u m of a l l f o r c e s in the r o l l b i t e . When v a r i -
a b l e s such a s flow s t r e s s , r o l l d e f o r m a t i o n and c o e f f i -
c i e n t of f r i c t i o n a r e e x p r e s s e d in t e r m s of the l o c a t i o n
of the s t r i p e l e m e n t , the d i f f e r e n t i a l equation can be
i n t e g r a t e d n u m e r i c a l l y , t a k i n g into account the p r o p e r
boundary conditions.
2. Continuous s t r a i n h a r d e n i n g within the r o l l b i t e
is c o n s i d e r e d , including s t r a i n r a t e e f f e c t s and p r i o r
VOLUME 5, DECEMBER 1 9 7 4 - 2 4 8 3
r e d u c t i o n . It was found for c o l d - r o l l e d a l u m i n u m that
s t a t i c t e n s i l e data obtained f r o m v a r i o u s l y cold worked
s a m p l e s a r e m o s t s u i t a b l e for flow s t r e s s input. It had
a p p e a r e d n e c e s s a r y to build a s p l i t - H o p k i n s o n b a r c o m -
p r e s s i o n t e s t m a c h i n e for this p u r p o s e . This was done
and e x t e n s i v e high s t r a i n r a t e data for t h r e e a l u m i n u m
a l l o y s w e r e developed. Unexpectedly, however, the
s t r a i n r a t e effects d e t e r m i n e d f r o m the c o m p r e s s i o n
of s m a l l c y l i n d e r s did not a g r e e with the a n a l y s i s of
r o l l i n g data u s i n g the Hsu model. P e r h a p s d e f o r m a t i o n
m e c h a n i s m s in r o l l i n g a r e not a d e q u a t e l y s i m u l a t e d in
a c o m p r e s s i o n t e s t u s i n g s m a l l c y l i n d e r s , or p e r h a p s
the t e m p e r a t u r e r i s e d u r i n g cold r o l l i n g l o w e r s the
flow s t r e s s d i f f e r e n t l y . While this p r o b l e m is u n d e r
f u r t h e r study, use of s t a t i c t e n s i l e data for input flow
s t r e s s has yielded good r e s u l t s .
3. Roll d e f o r m a t i o n in t h e b i t e is solved u s i n g e l a s -
t i c i t y t h e o r y s i m i l a r to the a p p r o a c h e s of Cosse and
Economopoulous TM and Zorowski and Weinstein, zl and
the p r e s s u r e d i s t r i b u t i o n is obtained a s a r e s u l t of
the i t e r a t i v e p r o c e s s . Most models have used the s i m -
plifying a s s u m p t i o n that the r o l l d e f o r m s in a c i r c u l a r
a r c . The p r e s e n t model p r e d i c t s the exact d e f o r m a t i o n
shape, which g e n e r a l l y d e v i a t e s f r o m a c i r c u l a r a r c .
4. Another i m p o r t a n t f e a t u r e is the t r e a t m e n t of the
coefficient of f r i c t i o n . The m o d e l allows a n o n - c o n s t a n t
f r i c t i o n coefficient, c o n t r a r y to m o s t published m o d e l s .
Cheng ~ c o n s i d e r e d n o n - c o n s t a n t f r i c t i o n u n d e r h y d r o -
d y n a m i c l u b r i c a t i n g conditions. Nadai ~ c o n s i d e r e d s e v -
e r a l d i f f e r e n t a s s u m p t i o n s of f r i c t i o n within the r o l l
bite and i l l u s t r a t e d t h e i r effects on n o r m a l and t a n g e n -
t i a l p r e s s u r e d i s t r i b u t i o n s . By c o m p a r i n g N a d a i ' s c a l -
culated d i s t r i b u t i o n s with published e x p e r i m e n t a l p r e s -
s u r e d i s t r i b u t i o n s , it was o b s e r v e d that b e t t e r a g r e e -
m e n t can be achieved when the coefficient of f r i c t i o n
is a s s u m e d to be p r o p o r t i o n a l to the r e l a t i v e speed of
slip b e t w e e n r o l l and d e f o r m i n g s t r i p . Fig. 5 shows
how the s o - c a l l e d " f r i c t i o n h i l l , " n o r m a l s t r e s s vs
d i s t a n c e through bite, is e r r o n e o u s l y shaped in the
v i c i n i t y of the n e u t r a l plane when c a l c u l a t e d with c o n -
st.ant coefficient of f r i c t i o n and c o m p a r e d to m e a s u r e d
data. x~ T h e r e f o r e , the model was c o n s t r u c t e d with the
c a p a b i l i t y of defining coefficient of f r i c t i o n as any a r -
b i t r a r y function. Subsequent r u n s with the model i n -
deed c o n f i r m e d that coefficient of f r i c t i o n v a l u e s p r o -
p o r t i o n a l to s l i p p i n g speed b e t w e e n s t r i p and r o l l gave
r e s u l t s s u p e r i o r to the c o n s t a n t coefficient of f r i c t i o n
a s s u m p t i o n . This m a y indicate a s u b s t a n t i a l a m o u n t
of h y d r o d y n a m i c l u b r i c a t i o n , as s u g g e s t e d by Chang.
F o r c o n s t a n t total force, the p r e d i c t i o n of the location
of the n e u t r a l plane, and hence f o r w a r d slip, is s t r o n g l y
affected by the d i f f e r e n t t r e a t m e n t s of f r i c t i o n , as i l -
l u s t r a t e d in Fig. 6 in which both c u r v e s w e r e c a l c u -
lated with the Hsu model.
5. Another f a c t o r c o n s i d e r e d by the model is the
e l a s t i c s p r i n g - b a c k of the s t r i p as it exits the r o l l
bite. This is t r e a t e d as a s e p a r a t e step following the
m a i n solution of the g o v e r n i n g equation of e q u i l i b r i u m
of f o r c e s .
6. N o r m a l and t a n g e n t i a l s t r e s s a s weI1 as f r i c t i o n
and d e f o r m a t i o n e n e r g y d i s t r i b u t i o n s throughout the
bite a r e c a l c u l a t e d by the model. E x a m p l e s of these
d i s t r i b u t i o n s will be shown l a t e r in c o n n e c t i o n with a
p r o b l e m e x a m p l e . E n e r g y d i s t r i b u t i o n s a r e not c a l c u -
lated in s i m p l i f i e d models and would be somewhat e r -
r o n e o u s f r o m any m o d e l s a s s u m i n g c o n s t a n t f r i c t i o n .
C o r r e c t e n e r g y d i s t r i b u t i o n i n f o r m a t i o n is p a r t i c u l a r l y
i m p o r t a n t input to the heat p a r t i t i o n r o u t i n e of the E n -
e r g y Balance Model.
Energy Balance Model
Energy enters a mill as sensible heat in the strip
and from the drive motor turning the rolls. Energy
leaves a mill as sensible heat in the strip, in coolant
directly applied to the strip before and after the bite,
and in coolant applied to the work rolls and the backup

IOO
~ *-~ Neutral Plane
.•70
CI_
80 Normal Stress,
C
O0
O'3
\
60
Ld
O~
\
Z O3
/
9 /
F- 40 /
<I~60
/ Coef. Friction
Or"
/ Assumptions
}--
or) 20 / 0
S, eA Z
f
/ Constant

Function of
Strip-Roll
oo Differential
cO o Speed
I i
LLJ
F-
iN .,/
0'3 -20 _ Bite Length ~! 50
Bite Length I Entry Exit ]
_ Bite Len_thg _
Fig. 5--Comparison of calculated normal and frictional stress
distributions assuming constant coefficient of friction 11 with Fig. 6--Effect of friction assumption on location of neutral
measured values. 17 plane.

2484-VOLUME 5, DECEMBER 1974 METALLURGICALTRANSACTIONS

 2400
g 30 NODES
% 200(
~ 160(
U2
m
0
~ 120(
m IO NODES IN STRIP - ~ - p - ~
U-
80C
Z UNIFORM SPACING
Oil-Bose Coolont
i-- 4 0 0
kd
,, ~,, ~,, & . . . . . .
0 5 0 6 0 9 0 1200 1500
STRIP SPEED (fpm)
Fig. 7--Meat transfer coefficient v s s t r i p speed.
r o l l s . The t h r e e r o u t i n e s in the E n e r g y B a l a n c e Model
which a c c o u n t for the e n e r g y flows into and out of a
m i l l a r e s t r i p cooling, h e a t p a r t i t i o n , and r o l l t e m p e r -
ature.
Strip Cooling Routine. The s t r i p e n t e r i n g a r o l l s t a n d
m a y have r e s i d u a l h e a t f r o m hot r o l l i n g , a n n e a l i n g f u r -
n a c e s , o r p r e v i o u s cold r e d u c t i o n s . N o r m a l l y , the s t r i p
is quenched b y coolant a s it a p p r o a c h e s the b i t e . T h i s
c o o l a n t m a y b e a p p l i e d i n t e n t i o n a l l y o r m a y be only a
puddle of r o l l coolant flowing out onto the s t r i p . The
quench effect of t h i s l a t t e r c a s e was m e a s u r e d in t e s t s
in an i n s t r u m e n t e d K a i s e r p r o d u c t i o n m i l l . T e m p e r a -
t u r e d r o p of w a r m s t r i p p a s s i n g t h r o u g h the m i l l at
v a r i o u s s p e e d s but with no r e d u c t i o n was m e a s u r e d
u s i n g both o i l - b a s e and w a t e r - b a s e c o o l a n t s . The c a l -
c u l a t e d h e a t t r a n s f e r c o e f f i c i e n t s of t h e s e two c o o l a n t s
a s a function of s t r i p s p e e d a r e shown in Fig. 7. As
e x p e c t e d , the quench effect of the w a t e r - b a s e c o o l a n t
was f o u r to five t i m e s that of the o i l - b a s e coolant.
The d a t a f r o m F i g . 7 allow the c a l c u l a t i o n of the
t e m p e r a t u r e change of the s t r i p f r o m e n t r y to the m i l l
s t a n d to b i t e e n t r y . T h i s c a l c u l a t i o n is b a s e d on the
a s s u m p t i o n s that the s t r i p is a v e r y good c o n d u c t o r ,
i.e., that its t e m p e r a t u r e is v e r y n e a r l y u n i f o r m
throughout the t h i c k n e s s , and t h a t the heat t r a n s f e r
c o e f f i c i e n t is not g r e a t l y a f f e c t e d b y t e m p e r a t u r e in
the r a n g e of i n t e r e s t . T h e s e quench zone a s s u m p t i o n s
a r e the s a m e a s t h o s e u s e d b y R o b e r t s . 24
The next s t e p is to c a l c u l a t e the h e a t flows and t e m -
p e r a t u r e s of r o l l and s t r i p a s t h e y p r o g r e s s through
the b i t e . Any s t r i p quenching that m u s t be c o n s i d e r e d
a f t e r e m e r g e n c e f r o m the b i t e is done b y a g a i n c a l l i n g
on the s t r i p c o o l i n g r o u t i n e .
Heat Partition Routine. This r o u t i n e c a l c u l a t e s the
t r a n s i e n t h e a t flow b e t w e e n s t r i p and r o l l throughout
the c o n t a c t length of the r o l l b i t e . A g e n e r a l p u r p o s e
t h e r m a l a n a l y z e r c o m p u t e r p r o g r a m c a l l e d SINDA ~'~6
is u t i l i z e d . A n u m e r i c a n a l y s i s s o l u t i o n is p r o v i d e d
u s i n g finite d i f f e r e n c e s .
V a l u a b l e f e a t u r e s of t h i s c o m p u t e r p r o g r a m f o r
p r e s e n t p u r p o s e s include: (1) a l a r g e v a r i e t y of e f f i -
cient s t e a d y - s t a t e and t r a n s i e n t e x e c u t i o n r o u t i n e s ;
(2) a b i l i t y to handle a l l t h r e e m o d e s of h e a t flow (con-
duction, convection and r a d i a t i o n ) ; (3) e a s y handling of
n o n l i n e a r i t i e s ; (4) a l l o w a n c e of u s e r - s p e c i f i e d c a l c u l a -
tions within the f r a m e w o r k of the n e t w o r k s o l u t i o n ; (5)
node and c o n d u c t o r g e n e r a t i n g r o u t i n e s for up to t h r e e
METALLURGICAL TRANSACTIONS
\ #~/ /~-000 BITE ANGLE
IN ROLL, . ~'~. 9
LOG SPACING~ . " \ ~- "
o- 9 o ~-'_#-
0 L/OXIDE"~C.: : ~_~,L-_Z
FILM ~ _~ t ~c_
OLLING'
HALF-THICKNESS -'[~---L ~ - ~ - ~ _ ~ % ~ - DIRECTION
I ~ -~'-
I , 9 I :::::~t---_,L= STRIP
F i g . 8 - - H e a t p a r t i t i o n n e t w o r k in p o r t i o n of r o l l b i t e c r o s s
section.
d i m e n s i o n s ; and (6) i n t e r f a c i n g with a c o m m o n d a t a
b a s e u t i l i z e d b y a l l the r o i l i n g m o d e l s .
Although the SINDA s y s t e m i t s e l f is t o t a l l y g e n e r a l ,
it is p o s s i b l e to use the p r e p r o c e s s o r of SINDA to g e n -
e r a t e and s a v e a s p e c i f i c c o m p i l e d model, which can
then b e u s e d r e p e a t e d l y without f u r t h e r r e c o u r s e to t h e
p r e p r o c e s s o r . Such a s p e c i f i c m o d e l can s t i l l be g e n -
e r a l in t e r m s of d i m e n s i o n s and o p e r a t i n g p a r a m e t e r s
and can t r e a t such p a r a m e t e r s a s input data.
The n e t w o r k u t i l i z e d for the h e a t p a r t i t i o n s o l u t i o n
e n c o m p a s s e s half the s t r i p t h i c k n e s s and the s u r f a c e
o r " t h e r m a l t i r e " p o r t i o n of a r a d i a l wedge of the r o l l .
As shown in F i g . 8, t e n n o d e s a r e d i s t r i b u t e d u n i f o r m l y
through the s e m i - t h i c k n e s s of the s t r i p and 30 nodes
a r e d i s t r i b u t e d l o g a r i t h m i c a l l y in the o u t e r 1 in. of the
r o l l wedge, w h e r e v i r t u a l l y a l l of the r o l l t h e r m a l g r a -
d i e n t e x i s t s d u r i n g b i t e . The r o l l wedge is c h o s e n to
b e 1/500 of the a n g u l a r r e g i o n defined b y the b i t e . The
l o n g i t u d i n a l and l a t e r a l d i m e n s i o n s of the s t r i p n e t w o r k
a r e at a l l t i m e s k e p t equal to the v e r t i c a l p r o j e c t i o n of
the s u r f a c e of the r o l l wedge n e t w o r k . As a c o n s e -
quence, the a m o u n t of m a t t e r e n c o m p a s s e d within the
s t r i p n e t w o r k c o n t i n u o u s l y c h a n g e s a s the s t r i p u n d e r -
goes r e d u c t i o n t h r o u g h the b i t e and a s the p r o j e c t i o n
of the r o l l n e t w o r k c h a n g e s through the b i t e . The r o l l
m e s h , on the o t h e r hand, is a s s u m e d unchanged a s it
p a s s e s t h r o u g h the b i t e . That i s , the e l a s t i c d e f o r m a -
tion of the r o l l is a s s u m e d i n s i g n i f i c a n t in changing
the t h e r m a l flow within the r o l l s u r f a c e . The e x a c t
s h a p e of the a r c of c o n t a c t within the b i t e a r e a is b a s e d
upon c a l c u l a t i o n s of the Hsu F o r c e - T o r q u e - S l i p Model,
which the h e a t p a r t i t i o n r o u t i n e c a l l s upon d i r e c t l y .
In a d d i t i o n to the nodes l o c a t e d within the b o d i e s of
the s t r i p and r o l l , nodes a r e a l s o l o c a t e d on t h e i r s u r -
f a c e s . T h e s e s u r f a c e nodes a r e c o n n e c t e d through a
c o n d u c t a n c e e l e m e n t which s i m u l a t e s the oxide and
l u b r i c a n t f i l m s e p a r a t i n g the s u r f a c e s . The v a l u e of
t h i s conductance is d e t e r m i n e d b y c o m p a r i n g m e a s u r e d
and p r e d i c t e d r o l l and s t r i p t e m p e r a t u r e s , using a
r a n g e of a s s u m e d c o n d u c t a n c e s . The c o n d u c t a n c e s
r a n g e d f r o m 80,000 to 250,000 B t u / f t 2 - h - ~ but w e r e
m o s t l y c l u s t e r e d at 150,000 ~=30,000.
The d e f o r m a t i o n e n e r g y and f r i c t i o n e n e r g y d i s s i -
p a t e d within the r o l l b i t e a r e c a l c u l a t e d f r o m the Hsu
F o r c e - T o r q u e - S l i p Model. It is a s s u m e d that 96 p c t
of the d e f o r m a t i o n e n e r g y is d i s s i p a t e d u n i f o r m l y
t h r o u g h the s t r i p t h i c k n e s s a s heat, while the f r i c t i o n
e n e r g y is d i v i d e d e q u a l l y b e t w e e n the r o l l and s t r i p
s u r f a c e nodes. The r e m a i n i n g 4 pct of the d e f o r m a t i o n
e n e r g y b e c o m e s s t o r e d e n e r g y in the s t r i p . The d i s -
t r i b u t i o n of the d e f o r m a t i o n and f r i c t i o n e n e r g i e s
VOLUME 5, DECEMBER 1 9 7 4 - 2 4 8 5
through the bite is n o n u n i f o r m and is therefore a func-
tion of position within the bite as calculated by the Hsu
model.
Cerni et al aT and Peck e t a128 assumed averaged and
uniform deformation and friction energy sources
through the arc of contact based on an average strip
velocity. Parke and Baker29 elected to divide the roll
bite into four distinct heat transfer zones, treating
each one s e p a r a t e l y . S e r e d y n s k i ~~ and B r a d l e y e t a l a~
a s s u m e d heat supplied to the r o l l s was p r o p o r t i o n a l to
the r o l l bite contact a r e a , t e m p e r a t u r e d i f f e r e n c e b e -
tween s t r i p and r o l l , and t i m e of contact. D a l h e i m e r 32
c o n f i r m e d the s t r o n g d e p e n d e n c e of heat t r a n s f e r in
the contact a r e a due to i n t e r m e d i a t e l a y e r s of m a t e -
r i a l such as oxide coating and l u b r i c a n t f i l m . F i o r e n -
tino e t a l ~3 a g r e e d that heat g e n e r a t i o n r a t e s within the
c o n t a c t zone could be d e r i v e d f r o m s l i p - l i n e theory,
but i n s t e a d used a v e r a g e v a l u e s a s a f i r s t - o r d e r e s t i -
m a t e . Steindl and Rice, 34 Koot,6 and Inhaber3s ac- Fig. 9--Roll coolingtest rig.
counted for the noncontinuousheat generation through
the roll bite as a function of relative speed between
strip and roll, material properties, and stresses.
[
LI_ I 0 0 0
Inhaber and others also confirmed that a portion (2 to ~I

5 pct) of the deformation energy generated in the roll ,-F

bite remains latent in the strip as stored energy.
8o0
In the present model, the heat flow and tempera-
rTl
tures are calculated at 500 equal time intervals, each
one corresponding to movement of the roll through an LL
IJJ 6 0 0
angle equivalent to the roll wedge. The temperatures 0
of the roll wedge and strip are assumed uniformim- 0
r'r"
mediately before contact. Heat flows into and out of Ill
each node and into and out of the entire network are D_ 4 0 0
O0 Puddle
integrated at each time step and are available as a
check at the end of the bite. [32
The model provides a summation of heat flow to the b-" 2OO
roll, strip, and coolant. Roll and strip temperatures
throughout the bite and the average exiting strip tem- L.!_I zzteLocotions

perature are outputs. -:- t ..... t ,

N o m i n a l R o l l T e m p e r a t u r e R o u t i n e . The r o l l t e m -
perature routine assumes steady-state temperature
and heat flow conditions. At this stage it a l s o a s s u m e s
u n i f o r m t e m p e r a t u r e s and no heat flow in the width d i -
r e c t i o n . V a r i a t i o n s of t h e s e p a r a m e t e r s in the width
d i r e c t i o n a r e p r o v i d e d l a t e r , in the Roll T h e r m a l C a m -
b e r Model.
A heat flow b a l a n c e on the work r o l l s is made b y s e t -
ting the heat flow to the work r o l l s (from the heat p a r -
t i t i o n r o u t i n e ) equal to the s u m of l o s s e s to the work
r o l l and backup r o l l coolants. All heat flow to the b a c k -
up r o l l is a s s u m e d to be b y conduction f r o m the work
roll.
The heat flow to the r o l l s is a function of r o l l and
s t r i p t e m p e r a t u r e s e n t e r i n g the bite. The heat p a r t i -
tion r o u t i n e s o l v e s for the heat flow over a wide r a n g e
of e n t e r i n g r o l l and s t r i p t e m p e r a t u r e s and c a l c u l a t e s
a f u n c t i o n a l r e l a t i o n s h i p which then is provided to the
n o m i n a l r o l l t e m p e r a t u r e r o u t i n e for each c a s e .
The work r o l l s a r e cooled with s p r a y s which m a y
i m p i n g e at s e v e r a l l o c a t i o n s both on the e n t r y and exit
s i d e s . In o r d e r to d e t e r m i n e the o p t i m u m location,
angle, p r e s s u r e , and n o z z l e type for the s p r a y s , as
well as to p r o v i d e heat t r a n s f e r data for the models,
a s p e c i a l r o l l cooling t e s t rig, shown in Fig. 9, was
c o n s t r u c t e d . A 90 kW r a d i a n t lamp h e a t e r is located
on one side of a 20-in. d i a m e t e r roll, and e x p e r i m e n -
0 0o 90 o 180 ~
ANGULAR POSITION ON ROLL
Fig. 10--Local instantaneousheat transfer coefficientprofile
for three rows of close-spaced nozzles.
tel cooling e q u i p m e n t is located on the other side. The
steel roll is hollow and has a 0.012-in. thick copper
window bonded to an epoxy insulator to serve as a
slope calorimeter. A thermocouple employing0.001-
in. diameter wires is welded to the backside of the
copper window. Oscillographic recordings of the ther-
mocouple output, transmitted via an internally mounted
FM radio system, provide data for the calculation of
local instantaneous heat transfer coefficient throughout
the quench zone. Extensive roll cooling data have been
accumulated for many spray patterns employingboth
oil-base and water-base coolants.
An example of a heat transfer coefficient profile is
shown in Fig. 10. The overall thermal conductanceof
the cooling zone is obtained by integrating the area
under the heat transfer coefficient curve.
In the course of the work with the roll cooling rig,
means were found to increase the cooling efficiency
of several production mills by a factor of four without
increasing the supply volume or pressure, or chang-
ing the coolant composition. This was one of those
early practical results which engendered considerable

2486-VOLUME 5,DECEMBER 1974 METALLURGICAL TRANSACTIONS

e n t h u s i a s m in p r o d u c t i o n m a n a g e m e n t for a c c e l e r a t e d
p u r s u i t of the p r o j e c t .
The h e a t flow f r o m the b a c k u p r o l l s to c o o l a n t is
c o m p u t e d f r o m the t h e r m a l conductance of the s p r a y s
a p p l i e d to the b a c k u p r o l l and the e m p i r i c a l o b s e r v a -
tion t h a t the t e m p e r a t u r e d i f f e r e n c e b e t w e e n b a c k u p
r o l l s and c o o l a n t n o r m a l l y is c l o s e to o n e - t h i r d that
b e t w e e n w o r k r o l l s and c o o l a n t . This a s s u m p t i o n s i m -
p l i f i e s the s o l u t i o n of the w o r k r o l l h e a t flow b a l a n c e
and n o m i n a l r o l l t e m p e r a t u r e .
The e n e r g y b a l a n c e d i s c u s s e d thus f a r was s i m p l i -
fied b y c o n s i d e r i n g only one m i l l stand. L a t e r , m u l t i -
s t a n d m a s s and e n e r g y b a l a n c e p r o g r a m s will be c o n -
s i d e r e d . T h e y will show how the m o d e l s a r e c o m b i n e d .
R o l l T h e r m a l C a m b e r Model
The p u r p o s e of the Roll T h e r m a l C a m b e r Model is
to c a l c u l a t e the t h e r m a l e x p a n s i o n of the w o r k r o l l s
v s width. Heating and c o o l i n g both v a r y a c r o s s the
width, l e a d i n g to t h e r m a l d i s t o r t i o n . This d i s t o r t i o n
not only a f f e c t s p r o d u c t f l a t n e s s , but a l s o w e a r and
life of the r o l l . F u r t h e r m o r e , e x c e s s i v e w o r k r o l l
t e m p e r a t u r e , and t h e r e f o r e c a m b e r , often l i m i t s p r o -
duction s p e e d . Thus, d e v e l o p m e n t of a m a t h e m a t i c a l
m o d e l r e l a t i n g r o l l t e m p e r a t u r e and shape to o t h e r
p r o c e s s i n g p a r a m e t e r s is i n d i s p e n s a b l e to e s t a b l i s h -
ing o p t i m u m d e s i g n , o p e r a t i n g , and p r o c e s s c o n t r o l
factors.
C o m p a r e d with s o m e o t h e r a s p e c t s of r o i l i n g , l i t t l e
h a s b e e n p u b l i s h e d c o n c e r n i n g the o v e r a l l r o l l t h e r m a l
p r o b l e m . A few c o m p r e h e n s i v e w o r k s have a p p e a r e d
in t h e p a s t few y e a r s , m o s t n o t a b l y t h o s e of C e r n i , z7
Peck, m P a r k e , 2 9 Hogshead,3S and Koot.6 The f i r s t four
w e r e c o n c e r n e d p r i m a r i l y with t h e r m a l v a r i a t i o n s
t h r o u g h the r o l l c r o s s s e c t i o n , but i g n o r e d the t h e r m a l
c a m b e r a s p e c t s in the a x i a l d i r e c t i o n . Koot a n a l y z e d
the t o t a l t h e r m a l r e l a t i o n s of the r o l l i n g p r o c e s s , i n -
cluding d i r e c t r e l a t i o n s h i p with the p r i m a r y r o l l i n g
p r o c e s s p a r a m e t e r s . P a r k e and Koot a p p e a r to have
p r o v i d e d the b e s t a c c o u n t i n g of the o v e r a l l heat b a l a n c e .
S e v e r a l o t h e r a u t h o r s , notably B e c k e r and Konig, 37
Polukhin, 38 B e e s t o n and E d w a r d s , 39 and W i l m o t t e and
Mignon, ~ have i n v e s t i g a t e d the t h e r m a l c a m b e r along
the r o l l b a r r e l . T h e s e w o r k s , h o w e v e r , u s e d s i m p l i -
f i e d and l e s s e x a c t s o l u t i o n s of the r o l l c r o s s - s e c t i o n
h e a t b a l a n c e . The p r i m a r y e f f o r t of B e e s t o n and E d -
w a r d s was d e v e l o p m e n t of a s i m p l i f i e d m o d e l for r e a l -
t i m e , o n - l i n e p r o c e s s c o m p u t e r c o n t r o l , r a t h e r than a
m o r e c o m p r e h e n s i v e m o d e l f o r p a r a m e t e r and d e s i g n
studies.
The p r e s e n t e f f o r t was d i r e c t e d t o w a r d d e v e l o p m e n t
of a c o m p r e h e n s i v e Roll T h e r m a l C a m b e r Model along
the s a m e l i n e s a s P a r k e and Koot, i n c l u d i n g i n c o r p o r a -
tion of the t h r e e - d i m e n s i o n a l a s p e c t a l o n g the r o l l width.
The e n t e r i n g s t r i p t e m p e r a t u r e is a s s u m e d to b e c o n -
s t a n t a c r o s s the width. Heat flow to the r o l l v a r i e s with
width d e p e n d i n g on the l o c a l d i f f e r e n c e in r o l l and s t r i p
t e m p e r a t u r e e n t e r i n g the b i t e . This is p a r t i c u l a r l y i m -
p o r t a n t b e c a u s e l a r g e v a r i a t i o n s in r o l l t e m p e r a t u r e s
m a y o c c u r due to m a n i p u l a t i o n of i n d i v i d u a l c o o l i n g
zones and a x i a l conduction. An a s s u m p t i o n of c o n s t a n t
h e a t input could l e a d to quite e r r o n e o u s r e s u l t s . The
p r o g r a m a l l o w s p r e s s u r e m o d u l a t i n g of each s p r a y
zone ( t y p i c a l l y 2 - i n . wide) to a d j u s t t h e r m a l c a m b e r s .
METALLURGICAL TRANSACTIONS
Heat l o s s to b a c k u p r o l l s and b a c k u p r o l l c o o l a n t is
c a l c u l a t e d by the E n e r g y B a l a n c e Model d e s c r i b e d
earlier.
Heat r e m o v a l b y the c o o l a n t s p r a y s can be t r e a t e d
b y e i t h e r of two a p p r o a c h e s . F o r t r a n s i e n t conditions,
the h e a t t r a n s f e r c o e f f i c i e n t of the s p r a y s can be f o r -
m u l a t e d a s a function of p o s i t i o n on the r o l l c i r c u m -
ference. For equilibrium steady-state conditions, a
t o t a l t h e r m a l conductance a r o u n d the r o l l c i r c u m f e r -
ence can be used. F o r e i t h e r c a s e , the h e a t t r a n s f e r
p r o p e r t i e s of the coolant s p r a y s w e r e d e t e r m i n e d e x -
p e r i m e n t a l l y on the m o c k - u p r o l l c o o l i n g r i g for s p e -
c i f i c s p r a y p a t t e r n s , c o o l a n t flows, and r o l l v e l o c i t i e s ,
as described earlier.
E x c e p t for P a r k e , Koot, Hogshead, and W i l m o t t e and
Mignon, m o s t r e s e a r c h e r s have n e g l e c t e d the c o o l i n g
quench of the b a c k u p r o l l s . Like P a r k e , the p r e s e n t
s t u d y concluded that the h e a t t r a n s f e r r e d a c r o s s the
w o r k / b a c k u p r o l l i n t e r f a c e can be quite i m p o r t a n t . A c -
c o r d i n g l y , the h e a t b a l a n c e d e v e l o p e d i n c l u d e s this e f -
f e c t a s a function of the t e m p e r a t u r e d i f f e r e n t i a l and
the net effective t h e r m a l conductance of the b a c k u p
r o l l sprays.
The m o d e l u t i l i z e s a f i n i t e - d i f f e r e n c e n u m e r i c a l s o -
lution s i m i l a r to that u s e d b y l>arke. The r o l l c r o s s -
s e c t i o n n e t w o r k is divided c i r c u m f e r e n t i a l l y by r a d i a l
l i n e s into s m a l l w e d g e s ; and r a d i a l l y b y c o n c e n t r i c c i r -
c l e s into l a y e r s of equal o r v a r y i n g t h i c k n e s s . The
w o r k r o l l width is d i v i d e d into a n u m b e r of equal s e g -
m e n t s . S y m m e t r y about the r o l l c e n t e r line is a s s u m e d .
The n e t w o r k i s p s e u d o t h r e e - d i m e n s i o n a l . E a c h v o l u -
m e t r i c e l e m e n t node is i n t e r c o n n e c t e d r a d i a l l y and a x -
i a l l y with its n e i g h b o r i n g e l e m e n t n o d e s . No h e a t c o n -
duction is a l l o w e d in the c i r c u m f e r e n t i a l d i r e c t i o n , an
a s s u m p t i o n that is r e a l i s t i c b e c a u s e of the high r o l l
r o t a t i o n a l s p e e d s and b e c a u s e s t e e l is a r e l a t i v e l y p o o r
t h e r m a l c o n d u c t o r . The t h i r d d i m e n s i o n is o b t a i n e d b y
r o t a t i n g the e l e m e n t a l wedge through c i r c u m f e r e n t i a l
b o u n d a r y c o n d i t i o n s a s a function of t i m e . In addition,
no h e a t l o s s e s o r gains a r e a s s u m e d at the r o l l b a r r e l
ends.
D u r i n g d e v e l o p m e n t of the m o d e l , t h i s t r a n s i e n t n e t -
w o r k solution was four~d to r e q u i r e a l a r g e amount of
c o m p u t e - t i m e . In addition, it was d e t e r m i n e d t h a t for
m o s t m i l l s t u d i e s , an e q u i l i b r i u m s t e a d y - s t a t e solution
was sufficient. C o n s e q u e n t l y , the m o d e l was m o d i f i e d
f o r e q u i l i b r i u m solution b y s i m p l y a l l o w i n g the r a d i a l
w e d g e s to b e c o m e one wedge c o v e r i n g the e n t i r e c i r -
cumference.
It was found, in c o m m o n with P a r k e , Peck, and o t h -
e r s , that the p r i m a r y a r e a of h e a t t r a n s f e r was in the
o u t e r l a y e r s o r " t h e r m a l t i r e " of the w o r k r o l l . R a t h e r
than i g n o r e the c e n t e r c o r e of the r o l l , it p r o v e d b e s t
to u s e a Iogar~thmic t h i c k n e s s variation of the r a d i a l
e l e m e n t s . The p r e s e n t m o d e l is a 5 b y 20 r a d i a l - a x i a l
n e t w o r k , although any n e t w o r k s i z e can be s p e c i f i e d .
Network c o n d u c t a n c e s and c a p a c i t a n c e s a s functions
of t e m p e r a t u r e a r e updated e v e r y 5 i t e r a t i o n s . Heat
conducted into the r o l l is updated e v e r y i t e r a t i o n a s a
function of the a c t u a l r o l l s u r f a c e t e m p e r a t u r e at the
s t a r t of that i t e r a t i o n . C a l c u l a t i o n s t a b i l i t y and s t e a d y -
s t a t e c r i t e r i a a r e a l s o i m p o s e d on t h e n e t w o r k solution.
Along the r o l l a x i s f r o m c e n t e r line to r o l l end, the
20 n e t w o r k e l e m e n t s at the s u r f a c e a r e s u b d i v i d e d f u r -
t h e r to p r o v i d e i n t e g r a t e d and weighted a v e r a g e s of r o l l
VOLUME 5, DECEMBER 1 9 7 4 - 2 4 8 7
b i t e h e a t inputs, coolant t h e r m a l c o n d u c t a n c e s , and INPUT DATA
t e m p e r a t u r e s . Heat t r a n s f e r to the b a c k u p r o l l s is c o n -
s i d e r e d to be u n i f o r m a c r o s s the r o l l i n t e r f a c e . C o o l - Roll Dimensions
ing p a t t e r n s (e.g., zone off-on, zone p r e s s u r e , puddle,
and r o l l end r u n - o f f ) and t e m p e r a t u r e v a r i a t i o n s of
I
E Entry Strip Dimensions
c o o l a n t m a y be s p e c i f i e d in any d e s i r e d m a n n e r a c r o s s
the r o l l f a c e .
!
N e t w o r k solution of the h e a t b a l a n c e and h e a t c o n - Strip Tension Distributions
duction throughout the w o r k r o l l body u t i l i z e s the SINDA
c o m p u t e r p r o g r a m r e f e r r e d to p r e v i o u s l y . Once the
I
Bending Jack Forces
n e t w o r k solution h a s b e e n a c h i e v e d , the e q u i l i b r i u m
t e m p e r a t u r e s throughout the r o l l a r e a v a i l a b l e for t h e r - 1
m a l e x p a n s i o n c o m p u t a t i o n . T h e r m a l e x p a n s i o n of the Desired Reduction
r o l l a c r o s s the width is c a l c u l a t e d b y s u m m i n g the
I
t h e r m a l e x p a n s i o n of the nodes in each r a d i a l wedge
and a s s u m i n g no c o n s t r a i n t b e t w e e n a d j a c e n t e l e m e n t s .
[ M~II and Work Piece Properties
Although this technique of i n d e p e n d e n c e of width e l e - COMPUTATION
m e n t s d o e s i n t r o d u c e an e r r o r due to s h e a r s t r e s s e s x.
b e t w e e n a d j a c e n t e l e m e n t s , the e r r o r is n o r m a l l y ]ter~tlve Schemesfor Obtaining Compatible
s m a l l due to the f a c t that t e m p e r a t u r e v a r i e s s l o w l y PressureDistributions /
with a x i a l d i s t a n c e . In the v i c i n i t y of the s t r i p edge,
w h e r e a r a p i d d r o p in r o l l t e m p e r a t u r e s often o c c u r s , ~ OUTPUT PRINTOUT
the e r r o r m a y be of s e c o n d - o r d e r s i g n i f i c a n c e . B e e -
ston and E d w a r d s u s e d a weighted influence function to I I
s m o o t h the t h e r m a l c a m b e r p r o f i l e in the v i c i n i t y of WR/Strlp IWR/BUR l IExtStr'p I
the s t r i p edge. Such a technique is b e i n g e v a l u a t e d in
_Press.Dist. IPross. ITensi~ Dist'l
the p r o g r a m but is not y e t i n c o r p o r a t e d in the p r e s e n t
R o l l T h e r m a l C a m b e r Model. It i s b e l i e v e d that the
p r e s e n t m o d e l h a s a d e q u a t e a c c u r a c y f o r the intended
applications. Exit Str~p
Strain
JJ I WR/Strip [
Contact
~WR/ UR
ICon| tact
Profile ] Length LLenc h
R o l l Gap and S t r i p Shape Model
The m a i n p u r p o s e of t h i s m o d e l is to p r e d i c t exit Fig. l l - - F l o w chart of roll gap and strip shape model.
s t r i p t h i c k n e s s p r o f i l e and f l a t n e s s a s functions of
e n t r y s t r i p p r o f i l e and f l a t n e s s , e n t r y and e x i t s t r i p the P o i s s o n ' s r a t i o s t r a i n a s s o c i a t e d with the b e n d i n g
tensile stresses, roll bending jack pressures, mill s t r e s s e s o v e r e i t h e r the top o r b o t t o m half of the r o l l
s p e e d , and m e c h a n i c a l g r i n d and t h e r m a l c a m b e r p r o - c r o s s s e c t i o n . The s h e a r d i s p l a c e m e n t can a l s o b e
f i l e s of the w o r k and b a c k u p r o l l s . P o r t i o n s of t h e s e c a l c u l a t e d using e l e m e n t a r y b e a m t h e o r y . H o w e v e r ,
functional r e l a t i o n s have b e e n r e p o r t e d b y m a n y r e - in the c o u r s e of the p r e s e n t work, the s h e a r c o e f f i -
s e a r c h e r s , including O ' C o n n e r and W e i n s t e i n , 2 Kuhn cient was d e t e r m i n e d b y a m o d i f i e d p r o c e d u r e which
and W e i n s t e i n , 41 and Tong, et al. 42~43 H o w e v e r , none t a k e s into account not o n l y the t r a n s v e r s e s h e a r d i s -
of the p u b l i s h e d w o r k s s e e m s to d e a l with the c o m - p l a c e m e n t but a l s o a d i s p l a c e m e n t of the r o l l a x i s
p l e t e s e t of v a r i a b l e s . In the p r e s e n t work, the i n d i - c a u s e d b y d i f f e r e n c e s of l o n g i t u d i n a l P o i s s o n ' s r a t i o
v i d u a l effect of e a c h of t h e s e v a r i a b l e s is c o n s i d e r e d e x p a n s i o n f r o m top to b o t t o m of t h e r o l l s . The l o n g i -
and t h e i r c o m b i n e d effect is c o m p u t e d . This p e r m i t s tudinal P o i s s o n ' s r a t i o e x p a n s i o n is due to p r e s s u r e
c l o s e s i m u l a t i o n of the r o l l i n g c o n d i t i o n s on a p r o d u c - g r a d i e n t o v e r the height of the r o l l c r o s s s e c t i o n ; t h i s
tion m i l l . p r e s s u r e g r a d i e n t r e s u l t s f r o m the a p p l i e d s u r f a c e
The s t r u c t u r e of the Roll Gap and S t r i p Shape Model loading. The l o n g i t u d i n a l P o i s s o n ' s r a t i o effect is s i g -
is r e p r e s e n t e d b y the flow c h a r t shown in F i g . 11. With nificant and not c o n s i d e r e d in o t h e r m o d e l s , to the a u -
inputs of known p r o p e r t i e s , d e s i r e d o p e r a t i n g f a c t o r s t h o r ' s knowledge.
and outputs of the p r i o r m o d e l s , it p r e d i c t s m a n y m e - The c a l c u l a t i o n of l o c a l f l a t t e n i n g is m o r e c o m p l i -
c h a n i c a l q u a n t i t i e s , i n c l u d i n g e x i t s t r i p t h i c k n e s s and c a t e d than the o t h e r d i s p l a c e m e n t c o m p o n e n t s . Its e f -
d i f f e r e n t i a l s t r a i n p r o f i l e s a s well a s e n t r y and exit f e c t on the t o t a l r o l l d i s p l a c e m e n t is a l s o m o r e p r o -
s t r i p t e n s i o n d i s t r i b u t i o n s a c r o s s the width. nounced f o r m a n y p r a c t i c a l c a s e s . Kuhn and W e i n s t e i n ,
The c a l c u l a t i o n s of the w o r k r o l l gap, and t h e r e f o r e and O ' C o n n o r and W e i n s t e i n e m p l o y e d the B o u s s i n e s q ' s
e x i t s t r i p p r o f i l e , a r e c a r r i e d out in the following m a n - s o l u t i o n of e l a s t i c h a l f - s p a c e f o r c a l c u l a t i n g r o l l s u r -
n e r . F o r e a s e of a n a l y s i s , the r o l l s u r f a c e d i s p l a c e - f a c e flattening. Tong, et al, on the o t h e r hand, u s e d
m e n t is d i v i d e d into four d i f f e r e n t c o m p o n e n t s s i m i l a r F o e p p l ' s t w o - d i m e n s i o n a l c o n t a c t t h e o r y . The f o r m e r
to t h o s e of Kuhn and W e i n s t e i n : 4L bending, s h e a r , l o c a l h a s the d i s a d v a n t a g e of n e g l e c t i n g the s u r f a c e c u r v a -
f l a t t e n i n g and r a d i a l P o i s s o n ' s r a t i o e x p a n s i o n . The t u r e s of the r o i l s while the l a t t e r s u f f e r s the i n a c c u -
c a l c u l a t i o n of b e n d i n g d i s p l a c e m e n t is quite s t r a i g h t - r a c i e s a r i s i n g f r o m t h e width effect, e s p e c i a l l y when
f o r w a r d with the u s e of e l e m e n t a r y b e a m t h e o r y . The severely nonuniform pressure distribution exists
r a d i a l P o i s s o n ' s r a t i o d i s p l a c e m e n t is the r e s u l t of a c r o s s the width of the r o l l s . In the p r e s e n t work, the
b e n d i n g s t r e s s e s and can b e c a l c u l a t e d by i n t e g r a t i n g f l a t t e n i n g a l o n g the w o r k r o l l / s t r i p i n t e r f a c e is c a l c u -

2488-VOLUME 5, DECEMBER 1974 METALLURGICAL TRANSACTIONS

l a t e d u s i n g an i m p r o v e d v e r s i o n of the t h r e e - d i m e n -
s i o n a l e l a s t i c h a l f - s p a c e t h e o r y . It is b e l i e v e d that
t h i s a p p r o a c h is m o r e a p p r o p r i a t e in view of the a b r u p t
p r e s s u r e d r o p o u t s i d e the e d g e s of the s t r i p . The f l a t -
t e n i n g b e t w e e n the w o r k and b a c k u p r o l l s is c a l c u l a t e d
u s i n g the t w o - d i m e n s i o n a l c o n t a c t t h e o r y with a f o r -
m u l a d e v e l o p e d b y Loo. 44 This c h o i c e is d i c t a t e d b y
the m o r e p r o n o u n c e d c u r v a t u r e effect b e t w e e n two c o n -
v e x s u r f a c e s and the e x p e c t e d s m o o t h p r e s s u r e d i s t r i -
b u t i o n s a l o n g the i n t e r f a c e b e t w e e n w o r k r o l l and b a c k -
up r o l l .
An influence function was d e r i v e d f o r e a c h d i s p l a c e -
m e n t c o m p o n e n t . With the r o l l s d i v i d e d into m a n y s e g -
m e n t s , not n e c e s s a r i l y of the s a m e width, the net d i s -
p l a c e m e n t of the r o l l s f o r a given p r e s s u r e d i s t r i b u t i o n
can be d e t e r m i n e d b y f i r s t finding the effect of each
s e g m e n t u s i n g the influence functions and then s u m -
ming for all segments.
The d e s c r i p t i o n of r o l l d i s p l a c e m e n t a p p l i e s to r o l l s
with known p r e s s u r e d i s t r i b u t i o n . B e c a u s e p r e s s u r e
d i s t r i b u t i o n is not known a p r i o r i , the d i s p l a c e m e n t s
and p r e s s u r e d i s t r i b u t i o n s have to be c a l c u l a t e d s i m u l -
t a n e o u s l y . This is done b y t h r e e m a j o r i t e r a t i o n
s c h e m e s , e a c h of which s e a r c h e s f o r r o l l d i s p l a c e -
m e n t s o r s t r i p s t r a i n s that a r e c o m p a t i b l e with the
p r e s s u r e o r t e n s i o n d i s t r i b u t i o n s and m e c h a n i c a l c o n -
s t r a i n t s in a c o n v e r g i n g p r o c e d u r e . E x t e n s i v e use of
the F o r c e - T o r q u e - S l i p Model is r e q u i r e d .
M a j o r f e a t u r e s of the m o d e l include:
1. W o r k r o l l , d e f l e c t o r , o r b a c k u p r o l l j a c k f o r c e s
a r e c o n s i d e r e d a s input d a t a f o r o p t i m i z i n g s t r i p shape.
2. The r o l l and s t r i p p r o f i l e s a r e input a s r o l l r a -
dius d e v i a t i o n v s the d i s t a n c e f r o m the c e n t e r of the
m i l l , a s X - Y p a i r s . T h i s e n a b l e s the s p e c i f i c a t i o n of
any c o m p l i c a t e d r o l l and s t r i p p r o f i l e s .
MASTER PROGRAM
J I I
I i
I
I Common
I Data
I
I
Base
j Input
Stream
w
Every
Input
and
Stored ~-- Output
Data Variable
Each
Alloy
and
Constant
Data Link and Stored
.... Control Link Mill
Fig. 1 2 - - M a s t e r p r o g r a m and c o m m o n data b a s e .
METALLURGICAL TRANSACTIONS
3. P o s s i b l e end pinching of the w o r k r o l l s when
r o l l i n g thin s t r i p is t a k e n into account.
4. P o s s i b l e n o n - c o n t a c t i n g gaps a l o n g the w o r k r o l l /
b a c k u p r o l l i n t e r f a c e s , c a u s e d b y r o l l end r e l i e f s o r
a b r u p t change of r o l l p r o f i l e s , a r e t a k e n into account.
5. The i n t e r r e l a t i o n s b e t w e e n the d i s t r i b u t i o n s of
r o l l i n g p r e s s u r e s , s t r i p p r o f i l e s , and s t r i p t e n s i o n s
are considered.
The flow c h a r t shows only the s t a n d a r d output c o n -
f i g u r a t i o n . An option i s a v a i l a b l e w h e r e i n the d e s i r e d
exiting s t r i p s h a p e and s t r a i n d i s t r i b u t i o n a r e s p e c i -
f i e d and the output is the i d e a l w a r m s h a p e of the w o r k
r o l l . This shape is a c o m b i n a t i o n of the m e c h a n i c a l
shape and the t h e r m a l c a m b e r . This i m p o r t a n t c a p a b i l -
ity will be d i s c u s s e d in m o r e d e t a i l l a t e r . The v a r i o u s
outputs of this m o d e l will a l s o b e i l l u s t r a t e d in c o n n e c -
tion with an e x a m p l e of the c o m b i n e d m o d e l s .
COMBINING THE BASIC MODELS
Up to t h i s point we have c o n s i d e r e d the b a s i c b l o c k s
of the o v e r a l l m o d e l and t h e i r u s e f o r a s i n g l e r o l l i n g
m i l l stand. Two p r o g r a m s a r e now i n t r o d u c e d which
a r e for m u l t i s t a n d o r m u l t i p a s s s i t u a t i o n s . One is the
r e d u c t i o n s c h e d u l e p r o g r a m and the o t h e r is the m u l t i -
s t a n d e n e r g y b a l a n c e p r o g r a m . T h e s e a r e m a s s and
energy conservation programs that track these fac-
t o r s through a t a n d e m m i l l o r m u l t i p l e p a s s e s t h r o u g h
one o r s e v e r a l m i l l s .
R e d u c t i o n Schedule P r o g r a m
The p r i n c i p a l r e a s o n for t h i s p r o g r a m is to e n s u r e
the c o m p a t i b i l i t y of s t r i p s p e e d throughout a m u l t i -
s t a n d m i l l , and to f u r t h e r e n s u r e the c o m p a t i b i l i t y of
Reduction Schedule Progl
Multlstand Energy Balance Program
Force-Torque-Slip Model ]
I
Energy Balance Model
t 1
I
Thermal Camber Model
I
I
Roll Gap and Strip Shape ModeiI I
I
Output: Printing, Plotting
i
VOLUME 5, DECEMBER 1974-2489
s t r i p and r o l l speed at each stand of such a m i l l . To
do so, this p r o g r a m i n t e r n a l l y c a l l s upon the Hsu
F o r c e - T o r q u e - S l i P Model to c a l c u l a t e load, torque,
power, and f o r w a r d slip for each stand. F o r a m u l t i -
s t a n d m i l l , this p r o g r a m m u s t i t e r a t e to d e t e r m i n e
the i n d i v i d u a l s t a n d speed c o m p a t i b l e with the o v e r a l l
m a s s flow through the m i l l . A n u m b e r of options allow
the u s e r to d e s c r i b e the d e s i r e d p a s s s e q u e n c e at each
s t a n d in s e v e r a l ways: (1) f o r c e r a t i o s ; (2) g r o s s h o r s e -
power r a t i o s ; (3) r e d u c t i o n ; or (4) i n c o m i n g and out-
going gage.
T h e s e options r e q u i r e the u s e r to s p e c i f y a d e s i r e d
s p e e d on the l a s t stand. A l t e r n a t i v e s to this a r e a u t o -
m a t i c r o u t i n e s to d e t e r m i n e (1) the m a x i m u m speed
p e r m i s s i b l e within the c o n s t r a i n t s of speed cone and
h o r s e p o w e r for a given m i l l , or (2) the speed and r e -
duction s e q u e n c e which will give the s a m e specified
m a x i m u m r o l l t e m p e r a t u r e on each s t a n d u n d e r full
cooling conditions. This l a t t e r option involves a u t o -
m a t i c i t e r a t i o n of the e n e r g y b a l a n c e heat p a r t i t i o n
and s t r i p cool r o u t i n e s with the r e d u c t i o n schedule
program.
Multistand Energy Balance P r o g r a m
The p u r p o s e of this p r o g r a m is to p e r f o r m an o v e r -
all heat b a l a n c e c a l c u l a t i o n of the e n t i r e r o l l i n g p r o -
c e s s in a m i l l equipped with any n u m b e r of stands and
s t r i p quench zones. This p r o g r a m p r o c e e d s s e q u e n -
t i a l l y through the m i l l in the r o l l i n g d i r e c t i o n . F o r
each s t r i p quench zone it c a l l s on the s t r i p cooling
r o u t i n e of the E n e r g y B a l a n c e Model d e s c r i b e d e a r -
l i e r . The p r o g r a m then c a l l s on the heat p a r t i t i o n and
n o m i n a l r o l l t e m p e r a t u r e r o u t i n e s for each stand, f e e d -
ing s t r i p t e m p e r a t u r e s f o r w a r d .
M a s t e r P r o g r a m and C o m m o n
Data Base
All of the m o d e l s d i s c u s s e d use i n t e r c h a n g e a b l e v a r i -
able n a m e s which p e r m i t p a s s i n g data back and forth
through a c o m m o n data b a s e , as shown in Fig. 12. A
m a s t e r p r o g r a m c o n t r o l s the s e q u e n c e of an a n a l y s i s .
Fig. 12 a l s o shows a s t o r e d p a r a m e t e r file which is a
powerful t i m e - s a v i n g tool as it r e d u c e s to an absolute
m i n i m u m the a m o u n t of input i n f o r m a t i o n r e q u i r e d .
F o r i n s t a n c e , a u s e r can input the n a m e of a c o m p a n y
r o l l i n g m i l l , which c a u s e s t r a n s f e r into the c o m m o n
data b a s e the following i n f o r m a t i o n specific to each
stand of that m i l l : work r o l l and backup r o l l d i m e n -
s i o n s ; b e n d i n g and deflector jack n u m b e r and d i a m e t e r ;
m o t o r e f f i c i e n c y ; b e a r i n g l o s s ; r a t e d h o r s e p o w e r and
speed; work r o l l and backup r o l l cooling t h e r m a l c o n -
d u c t a n c e vs speed and p r e s s u r e ; and t h e r m a l p r o p e r -
t i e s of r o l l m a t e r i a l s . The u s e r also inputs a l u b r i c a n t
code and an alloy and t e m p e r , which c a u s e s a n o t h e r
t r a n s f e r f r o m s t o r e d p a r a m e t e r s of flow s t r e s s data,
f r i c t i o n f a c t o r s , and t h e r m a l p r o p e r t i e s .
The m o d e l s , i n c l u d i n g the t h e r m a l nodal s y s t e m ,
a u t o m a t i c a l l y s i z e t h e m s e l v e s to the d i m e n s i o n s t r a n s -
f e r r e d to the c o m m o n data b a s e , which is a n e x t r e m e l y
useful aid in r a p i d p r o b l e m solving. It is r e l a t i v e l y
e a s y to i n c r e a s e the n u m b e r of r o l l i n g m i l l s , alloys,
and l u b r i c a n t s in the s t o r e d p a r a m e t e r file, and once
t h e r e , the data a r e v e r y c o n v e n i e n t l y a v a i l a b l e for use.
2490-VOLUME 5, DECEMBER 1974
Table I. Options for Solving the Rolling Model
Exit Strip WorkRoll WorkRoll WorkRoll
Solution Shapeand Mechanical Thermal Jack
Option Flatness Shape Camber Pressure
Strip Shape Result G G G
RollMechanical G Result G G
Shape -
RollThermal G G Result G
Camber
Jack Pressure G G G Resuli
IdealWarmWork G * * G
Roll Shape
G = Given.
*Result= Sumof these two.
With the m a s t e r p r o g r a m c o n t r o l l i n g the s e q u e n c e of
c a l c u l a t i o n s , m a n y p o s s i b l e c o m b i n a t i o n s e x i s t for u s -
ing the m o d e l s , depending on the p u r p o s e of an a n a l y -
s i s . A p a r t i a l l i s t of execution options is shown in
T a b l e I. F o u r b a s i c f a c t o r s which influence each other
a c r o s s the r o l l gap a r e : exiting s t r i p shape and f l a t -
n e s s , work r o l l m e c h a n i c a l shape, work r o l l t h e r m a l
c a m b e r , and work r o l l jack p r e s s u r e . Routines a r e
a v a i l a b l e , a s the table shows, that allow c a l c u l a t i o n of
any one of t h e s e f a c t o r s when the other t h r e e a r e s p e c -
ified. If backup r o l l b e n d i n g is a v a i l a b l e on a given
m i l l , it can be included as a fifth factor in the s e r i e s .
Another option, m e n t i o n e d e a r l i e r in the d i s c u s s i o n
of the Roll Gap and Strip Shape Model, is to c a l c u l a t e
the ideal w a r m work r o l l shape when d e s i r e d s t r i p
shape and a jack p r e s s u r e a r e provided. Two a p -
p r o a c h e s e x i s t for u s i n g the ideal w a r m r o l l shape
output. In one, a m e c h a n i c a l shape is given and s u b -
t r a c t e d f r o m the ideal w a r m shape. The r e s u l t of this
is the ideal t h e r m a l c a m b e r . Runs m a y then be made
u s i n g the Roll T h e r m a l C a m b e r Model to d e t e r m i n e
the o p t i m u m r o l l cooling s p r a y p r e s s u r e s and p a t t e r n s .
The other approach is to s u b t r a c t a given r o l l t h e r -
m a l c a m b e r f r o m the ideal w a r m r o l l shape to p r o v i d e
the ideal m e c h a n i c a l shape. Since it is not g e n e r a l l y
p r a c t i c a b l e to g r i n d c o m p l i c a t e d compound c u r v e s on
work r o l l s , a sine wave or p a r a b o l i c shape is usual.
A c c o r d i n g l y , a r o u t i n e m a y be s e l e c t e d to p r o v i d e a
b e s t - f i t s i n e wave to the ideal m e c h a n i c a l shape. The
effect of this c o m p r o m i s e on s t r i p f l a t n e s s can then
be found by use of the Roll Gap and Strip Shape Model.
ANALYSIS OF A TANDEM MILL
PROBLEM
T i m e p e r m i t s only a single e x a m p l e of application
of the o v e r a l l model to a n a l y s i s of a p r o b l e m in an a c -
tual m i l l . The one I have s e l e c t e d was an effort to d e -
t e r m i n e the f e a s i b i l i t y of r o l l i n g a p a r t i c u l a r alloy on
the c o m p a n y ' s o r i g i n a l , s m a l l f i v e - s t a n d cold m i l l u s -
ing full r a t e d h o r s e p o w e r on each stand, c o n c u r r e n t
with the i n s t a l l a t i o n of a second phase, i m p r o v e d r o l l
and s t r i p cooling s y s t e m .
P r e v i o u s r o l l i n g p r a c t i c e for this alloy used l e s s
than half the r a t e d power, l a r g e l y b e c a u s e e x c e s s i v e
c e n t e r b u c k l e s developed when the speed was i n c r e a s e d .
This p a r t i c u l a r m i l l is l u b r i c a t e d and cooled with a
m i n e r a l - o i l type coolant which, b e i n g a r e l a t i v e l y poor
METALLURGICAL TRANSACTIONS
 Table II. C o m p ~ Program ~intout

STAND NO. I STAND NO. 2 STANDNO, 3 STANDNO. 4 STAND NO, 5

PRIORD: 25.00
WR 01AM., I N . : 11.000 11.000 11.000 11.000 11,000
E N [ R Y ~A., IN.: .102U ,0532 .0410 .0273 .0198
EXIT h A . , I N . : .0632 .0410 .0273 o0198 .0135
WIDTH, I N . : 42.50 42.50 42.50 ~2.50 42.50
LNT TENSION,PSI: 1500.00 2000.00 2500.00 3000.00 4000.00
EAT TENSION,PSI: 2000.00 2500.00 3000.00 4000.00 6000.00
HEUUCTION, S: 38.01 35.17 33.42 27.52 31.80
SPEED, FPM: 585.07 912.55 1383.13 1907.36 2801.97
FORWARD S L I P , ~: 1.307 .241 -.709 -.683 -.862
POWER RATIO: .9996 1.0002 1.0006 .8003 1.0000
NET HORSEPOWER: Iili.92 1086o82 1048.35 773.40 915.82
b H O ~ HORSEPOWER: 1216.55 1217.21 1217.74 973.93 1217.01
IUTAL FORCE, LB: 782567.8 641087.2 520104.6 393046.4 352224.2
ROLL TEMP,, F, FC 131.60 1~3.00 144.27 132.01 145.20
BUR TEMP., F, FC: 103.87 107.67 108,09 10~.00 108.40
STRIP TEMP.,F=
ENIERING B I T E 117.53 166.38 185.17 186.81 172.28
EAITIN~ BIlE 203,08 242.45 256.18 240.25 245.15

COILING SPEED, FPM: 2777.83

COIL TEMP., F: 245.15

5000I with concave mechanical shapes, but this, in turn,

leads to another problem in mill start-up. At start-
2oooI up, the rolls do not have a thermal camber and large
0 edge waves are produced in the strip until the thermal
0
~-4,o [~176176
F
o"
crown becomes sufficiently large. Furthermore, the
combination of large thermal cambers and large con-
cave mechanical shapes in work rolls tends to produce
1500 I excessive quarter buckles in strip, as predicted by the
0 0 0 0 models and confirmedby mill experience.
I000 F 0

,~ I00 % RATEDON
ALL STANDS
Reduction Schedule Program
The reduction schedule program was employed as
the first step in analyzing the problem. Table II shows
the computer output of the reduction schedule program
O O for the particular aluminum alloy and temper under
3O O
study, using 0.102-in. entry gage and 0.0135-in. exit
z gage. The program automatically adjusted speed and
o 2o
o altered the reduction on each stand until it established
~J
I0 a combination which used full rated horsepower on
n~
each stand (nominally, 1250 hp on Stands I, 2, 3, 5 and
0 1000 hp on Stand 4).
Included in Table II are the accompanying outputs of
~> 750 the Force-Torque-Slip Model along with predictions
m~ 0 of nominal roll and strip temperatures from the En-
~Z 5ooI o ergy Balance Model. Plots of the data from Table FI
o o for all five stands are given in Fig. 13 for speed,
~ 250 I power, reduction, and force; and in Fig. 14 for for-
ward slip, bite length, flow stress, and energy.
o- I 4' 5' Shown in Figs. 15 and 16 for Stands 1 and 5 only are
STAND distributions through the bite of shear stress, normal
Fig. 13--Speed,power, reduction and separatingforce through pressure, differential speed between strip and roll,
five stands.
and strip thickness. These parameters are also ob-
tained as output from the Force-Torque-Slip-Model.
heat transfer medium, accounts for large thermal Note the absence of a neutral plane in Fig. 16. This
*,ers ~ d resultant center buckles. The problem is a result of the roll speed being higher than the ex-
could be alleviated in part by employing work rolls iting strip speed (negative forward slip).

METALLURGICAL TRANSACTIONS VOLUME 5, DECEMBER 1974-2491

 ~[ w . ~
0 0 0 0 uJ(~
9E ~- ..r
coco
O~-
o~
u_co

A 40

m~
025

O" I 0
0 O 0

o~
55

~ ~o
f 0 0 0 0 5C

500[
5: O"

a~-~
~
~-
3~f
zo.
,o
0
D
0
O
0
1:3 Total
0 Oef~
1 = 00201
9'~ Friction J
u~ 0
0,015
STAND

Fig. 1 4 - - F o r w a r d slip, bite len~th, flow s t r e s s , and e n e r g y H T

t h r o u g h five stands. co ~- 0,010" J

0.25 0.20 0.15 0,10 0.05 0
DISTANCE FROM ROLL AXIS PI_ANE (in.)
Fig. 16--Shear stress, normal pressure, differentia/ speed,
5 and thickness through bite of Stand 5.
2
uJ O
O

o ~ 2s
(n ~_J
~ --~
n- o
n<~D~2O
P-O
T
15

o
O
o
z 50 p[
9- t c 14

2oo ioo
l i gO__ o

?
o I ~ 4 5
STAND
Fig. 17--Energy partition through five stands.
c
O.IO
0.09 the e n t e r i n g s t r i p which would not have b e e n heated
by d e f o r m a t i o n in p r e v i o u s s t a n d s .
,~ 0.08
Fig. 18 i n d i c a t e s p r e d i c t e d r o l l and s t r i p t e m p e r a -
a_ 0.07 t u r e s through five s t a n d s with a P h a s e II i m p r o v e d
cooling s y s t e m b e i n g i n s t a l l e d on the m i l l . The lower
~0.06 r o l l t e m p e r a t u r e for Stand 4 is due to the lower h o r s e -
0.5 0.4 0.5 0.2 0.1 0.0
DISTANCE FROM ROLL AXIS PLANE (m.) power used on that stand in the schedule u n d e r c o n s i d -
Fig. 15-Shear stress, normal pressure, differential speed, and e r a t i o n . The s a m e data, for the p r e v i o u s Phase I i m -
thickness through bit of Stand 1. proved cooling, a r e shown in Fig. 19. The final s t r i p
shape depends l a r g e l y on what happens at Stand 5,
where the p r e d i c t e d work r o l l t e m p e r a t u r e s were de-
Multistand E n e r g y B a l a n c e P r o g r a m
c r e a s e d f r o m 186 to 145~ b y the m o d i f i c a t i o n s . The
Next, the a n a l y s i s employed the m u l t i s t a n d e n e r g y effect of this t e m p e r a t u r e d e c r e a s e on r o l l shape will
b a l a n c e p r o g r a m . Fig. 17 shows e n e r g y p a r t i t i o n to a be e l a b o r a t e d l a t e r .
r o l l in t e r m s of both heat flow and f r a c t i o n of total Fig. 20 shows, at the top, the d i s t r i b u t i o n of d e f o r -
bite e n e r g y through five s t a n d s . The low v a l u e s at m a t i o n and f r i c t i o n e n e r g i e s and, at the bottom, r o l l
Stand 1 a r e due p r i m a r i l y to the low t e m p e r a t u r e of and s t r i p t e m p e r a t u r e s , all as a function of d i s t a n c e

2492-VOLUME 5, DECEMBER 1974 METALLURGICAL TRANSACT|ONS

 \kr
~
240 1.2
b--
S_
C- ion
08
~ Strip v
200 >-
co 0,4
LL r-r-
Ld
v
0
160 Z
on/'->._
200[
OJ Work bJ
0 0
o Roils
~---- Slrip
120 Roll Average
A A z~Backup / Surface
z~ Rolls

8 0 j ~ - C~176
1801 ,./~"-" Surface
I I I , |
I 2 4
5 5 D_
STAND 160 ,/ .-/- / 5mils

Fig. 18--Ternperatures of rolls and strip through five stands, s

Phase II improved cooling.
~A 14.0 ~ i l s
56 mils
120
320

280
-k DISTANCE FROM ROLL AXIS PLANE (in.)
Fig. 20--Distribution of energy and temperature through roll
bite, Stand i.
240
LL
0

02 F- L2
~00
L~ 0 Work t
rnQtion

F- 0 0 Rolls 08

160 >-
(-9
O/ 0.4
Ld
& & Bockup
Z
LtJ
Frlction~ _
120 Roils
z~

Averoge
240 / --'~ ~ ~
BO I I L- I I ~ m Strip Surface
I 2 5 4 5 Roll ~ f/ -" ~

STAND 220 / / I #"

Fig. 19--Temperatures of r o i l s and strip through five stands, Surface
Phase I improved cooling. " ~ 200
vo
through the bite for Stand 1. Fig. 21 s h o w s the s a m e
:~ ~8o
p r e d i c t i o n s for Stand 5, w h e r e the bite is a p p r o x i m a t e l y
LJ
half as long. It is i n t e r e s t i n g to note that the r o l l s u r -
f a c e t e m p e r a t u r e m a k e s an i m m e d i a t e jump at the start 160
~ p
of the bite due to the high friction energy, but then r e - ~ ~ 15mils Deep
m a i n s n e a r l y constant through the r e s t of the bite, a c - 140 Entry Plane Exit Plane
tually dropping slightly in the middle. The interior of i
i i
the r o l l on the f i r s t stand at a depth of 0.005 in. s h o w s 0,24 020 OJ6 0,12 0.08 0,04 0 -0.04
a slight but continuous i n c r e a s e in t e m p e r a t u r e through- DISTANCE FROM ROLL AXIS PLANE(in.)
out the bite, while at 0.036 in. below the s u r f a c e , there
Fig. 21--Distribution of energy and temperature through roll
is p r a c t i c a l l y no change in t e m p e r a t u r e . On the fifth bite, Stand 5.
stand, there is a l m o s t no change in t e m p e r a t u r e 0.015-
in. below the s u r f a c e due to the higher speed and s h o r t e r
bite length. and diminished, as illustrated in Fig. 22. A trained
r o l l e r should be able to t h e r m a l l y shape the r o l l s to
c a m b e r s b e t w e e n those obtained through the use of
Roll T h e r m a l Camber Model
t h e s e two patterns. It is p o s s i b l e to turn off m o r e
In this a n a l y s i s the Roll T h e r m a l Camber Model was n o z z l e s to obtain s t i l l l a r g e r t h e r m a l c a m b e r s . How-
s e t up to allow on/off control of individual r o l l cooling e v e r , l a r g e r t h e r m a l c a m b e r s are undesirable b e c a u s e
s p r a y z o n e s . The t h e r m a l c a m b e r for all five stands they lead to t h r e e p r o b l e m s : (1) wide v a r i a t i o n s in strip
was calculated e m p l o y i n g two s p r a y patterns, full c o o l shape when individual c o i l s are started or rolling

METALLURGICALTRANSACTIONS VOLUME 5, DECEMBER 1974-2493

 221/zC_oo,ed Width
,, .__ Full Cool, Phase ]:
~ ' ~ . ~ (186"F)

O3
x O x O x O 0 0 0 ( xx \\ "~ Diminished,Phase~1
1,0'[[ ~ / \ ( 1 8 6 " F Peak,
TOP Diminished v IdealX \~-/" \ ,58~ Mean)
BOTTOM Spray Z \\ 9
O x O x O x O 0 0 ( xx
0rY 0.5 Full Cool, ~
(I49 ~
X - Nozzle OFF
._l
O-- Nozzle ON
0 0
01

<
0 0 0 0 0 0 0 0 0

_~oio ooo
TOP
BOTTOM

2~4~ Nozzle Spacing

21 I/4 Strip Edge
ooo

).
x

xx
x
Full Cool
Spray
-0,5

_1.00 I a
I0
DISTANCE FROM CENTER OF MiLL (in.)
,

Fig. 24--Work roll thermal and ideal profiles, Stand 5.

2:0
L 30

Fig. 22--Optional work roll cooling patterns.

Roll Gap and Strip Shape Model
The ideal w a r m shape of the work r o l l s with z e r o
b e n d i n g jack p r e s s u r e s was f i r s t c a l c u l a t e d , as shown
in F i g s . 23 and 24. It then a p p e a r e d that the c o r r e c t
s t r i p shape could be approached with full cooling and
1.5
E a flat m e c h a n i c a l g r i n d in Stands 2 through 5, and by
v
u s i n g full cooling and a 2 - m i l convex work r o l l g r i n d
Full Cool, Phase]I~ N r / (Di6ms~-hepdeoP~
use,]I
Z on Stand 1. Good shape on Stand 1 could a l t e r n a t i v e l y
I.O (134.5"Fi ~ 141*F Mean)
be obtained with flat work r o l l s and a d i m i n i s h e d c o o l -
O ing p a t t e r n , provided the t h e r m a l c a m b e r could be d e -
Or"
L_) veloped d u r i n g m i l l s t a r t - u p .
...j 0.5 With the b a s i c a n a l y s i s completed, t h e r e w e r e other
_J q u e s t i o n s that needed to be a n s w e r e d , p a r t i c u l a r y in
O
rY r e g a r d to effects which might be c a u s e d b y v a r i o u s
conditions of r o l l w e a r . It was i m p o r t a n t to p r e d i c t
rw the s i z e s and types of b u c k l e s which might be g e n e r -
O
ated by d i f f e r e n t backup r o l l wear conditions as well
_0,51~ , I I I I as the b e s t jack p r e s s u r e s and coolant p a t t e r n s for
[0 20 50
each wear c a s e . T h r e e c a s e s a r e e x a m i n e d : no wear,
DISTANCE FROM CENTER OF MILL (in.) 0.001 in. r a d i a l concave, and 0.001 in. convex backup
Fig. 23--Work roll thermal and ideal profiles, Stand 1. r o l l w e a r (based on p l a n t e x p e r i e n c e ) .
Effect of Flat Backup Rolls on Strip Shape. Fig. 25
i n d i c a t e s that with unworn fiat backup r o l l s (BUR), a
speeds a r e changed; (2) long t i m e s to obtain flat s t r i p work r o l l jack (WRJ) p r e s s u r e of z e r o is much b e t t e r
shape due to t h e r m a l lag; and (3) g r e a t e r t e n d e n c y to than one of 500 psi. The plots show s t r i p t h i c k n e s s p r o -
quarter buckles. f i l e s and s t r i p c r o w n p r o f i l e s v s width. In the p r e s e n t
The t h e r m a l c a m b e r s of the work r o l l s for full cool work, s t r i p c r o w n is defined as the p e r c e n t a g e of t h i c k -
and d i m i n i s h e d s p r a y p a t t e r n s a r e shown in F i g s . 23 n e s s d i f f e r e n c e at any location r e l a t i v e to the c e n t e r of
and 24 for Stands 1 and 5. The r o l l t e m p e r a t u r e s a r e the s t r i p . * The ideal s t r i p crown, b a s e d on expected
also noted. The full cool peak t e m p e r a t u r e s a r e close *The conventionaldefinitionof strip crownis thicknessdifferencein percent
to the n o m i n a l r o l l t e m p e r a t u r e c a l c u l a t e d e a r l i e r by relativeto the stripedge.However,it was foundthat the centeris a moreuseful
the m u l t i s t a n d e n e r g y b a l a n c e p r o g r a m . The " i d e a l " locationbecauseof (1) extremeedge thinning,(2) non-standardizedconvention
work r o l l shapes plotted in t h e s e f i g u r e s a r e those of the exactlocationto be usedin actualstripedge thicknessmeasurements,and
needed to obtain p e r f e c t s t r i p f l a t n e s s as d e t e r m i n e d (3) confusionof crowndatawhenedgesare trimmed.
by the Roll Gap and Strip Shape Model. If the full cool hot m i l l crown, is also shown in the f i g u r e . Introduced
t h e r m a l c a m b e r is l a r g e r than the ideal, c e n t e r b u c k l e s h e r e is the p r e d i c t e d s i z e of the b u c k l e s , m e a s u r e d in
cannot be p r e v e n t e d b y m a n i p u l a t i o n of the s p r a y s . The " I - u n i t s . " An I - u n i t denotes d i f f e r e n t i a l s t r a i n , i n . / i n .
only c a s e where this happens in this a n a l y s i s is in the x 10S--a convention employed by m a n y i n v e s t i g a t o r s .
upper c u r v e in Fig. 24 for full cool with the Phase I The d i f f e r e n t i a l s t r a i n s c a l c u l a t e d by the p r e s e n t model
i m p r o v e d cooling s y s t e m d i s c u s s e d e a r l i e r . In this m a y be somewhat l a r g e r than those that would be ob-
c a s e , p r o d u c t i o n e x p e r i e n c e did indeed c o n f i r m a c e n - t a i n e d b y e x p e r i m e n t a t i o n due to the fact that each e l e -
t e r buckle p r o b l e m . m e n t of width is a s s u m e d f r e e of c o n s t r a i n t by n e i g h -

2494-VOLUME 5, DECEMBER 1974 METALLURGICAL TRANSACTIONS

boring e l e m e n t s . Even so, the p r e d i c t i o n s are highly m e a s u r e of quarter buckle to i n c r e a s e s e v e n - f o l d ,
useful in a s s e s s i n g r e l a t i v e effects of Variables. In while the c e n t e r buckle would i n c r e a s e f i v e - f o l d .
this regard, Fig. 25 s h o w s that i n c r e a s i n g the jack A l a r g e number of v a r i a b l e s w e r e mentioned p r e v i -
p r e s s u r e f r o m z e r o to 500 psi would c a u s e the I-unit o u s l y in the d i s c u s s i o n of s t r i p t h i c k n e s s and crown
p r o f i l e s in connection with the Roll Gap and Strip Shape
Model. F i g s . 26 and 27 i l l u s t r a t e the r e l a t i v e i m p o r -
~G tance of s o m e of t h e s e f a c t o r s for Stand 5 in the p r e s -
WR BUR WRj I - Units ent e x a m p l e , with flat backup r o l l s and jack p r e s s u r e s
Curve Cool Coo1 Press Center quarter
of z e r o and 500 psi. Fig. 26 s h o w s the components of
a Full Full 0 695 330 backup r o l l d i s p l a c e m e n t s v s width, including bending,
b Full Full 500 3500 2290
CD w o r k r o l l / b a c k u p r o l l n o r m a l approach (flattening),
]Z
I--14
Q_
CC
Lf) 13 I l I
Zero WR j
~z
CI

H- O
Z Ideal Entry S t r i p . Z f
i,I f
W 500 psi ~NP'J -~"
C_)
(_9 <~ - 1 - -
_J
O_ Ck
09
C~
i.__ -5 I 1 I 1 (23 2
U) o 5 I0 15 20 25 _J
._J ~_~...~500 psi WRJ
DISTANCE FROM CENTER OF MILL (in.) orr~
~
. . . .

Fig. 2b--Stand 5 exit s t r i p shape, unworn backup rolls.

i I
I'o '
20 '
30 40
DISTANCE FROM CENTER OF MILL (in.)
Fig. 27--Components of work rolI d i s p l a c e m e n t s vs width,
m
Stand 5.

o 8000
<

UJ
(/)~- 500 psi WRJ U 600o
- 5 0 0 psi WRJ "~- ~\
zd_~ Zero psi WRJ / ~ /
l.d 0 Zero psi W R J ~
w~ 4000

J ~o
CL
2000
._! 500 psi WRJ
_J
0 ~
(3_122 Zero is[_.WR t I

y uJ 8000
(D 0
[K
0
133 I u-
uJ
o
~6ooo 500 psi WRJ ~ \~
Zero & 500 psi WRJ oc
uJ
F-

f
Z
Strip Edge ~ 1 [~-Elnd of BUR Borret
I .... |

I0 20 50 40 pp. 40000 t L _
to I0 ,.o
DISTANCE FROM CENTER OF MILL (in.) ~- DISTANCEFROM CENTER OF MILL (in.)
Fig. 26--Components of backup roll d i s p l a c e m e n t s vs width,
Stand 5. Fig. 28--Distribution of force vs width, Stand 5.

METALLURGICAL TRANSACTIONS VOLUME 5, DECEMBER 1974-2495

 WR BUR WRJ I - Units an edge pinch effect which gave a sudden r i s e in work
~15 Curve Cool Cool P r e s s Center quarte~
r o l l / s t r i p p r e s s u r e at the edge.
s a Full Center 0 Nil 650 Effect of Concave Backup Roll Wear on Strip Shape.
off
Y b Full Full 0 Nil 800 Fig. 29 shows how s t r i p t h i c k n e s s and c r o w n p r o f i l e s
0
a r e affected by concave backup r o l l w e a r . Two s p r a y
p a t t e r n s on the backup r o l l s w e r e studied. The effect
O_ of concave w e a r is to double the I - u n i t m e a s u r e of the
q u a r t e r b u c k l e s b y c o m p a r i s o n with the c a s e of flat
co L3 I I I I I
ground backup r o l l s , with o p t i m u m jack p r e s s u r e s
m a i n t a i n e d for each condition. C e n t e r b u c k l e s a r e
v 5
e l i m i n a t e d in this c a s e .
Effect of Convex Backup Roll Wear on Strip Shape.
Z
The e a s e of convex backup r o l l wear is given in Fig.
30. F o u r c o m b i n a t i o n s of jack p r e s s u r e s and backup
rY
r o l l cooling a r e t r e a t e d for p u r p o s e s of i l l u s t r a t i o n .
EL ~ P The use of deflector jacks (which bend the ends of the
O:: work r o l l s together) was found to give the b e s t s t r i p
l-- shape, 290 I - u n i t q u a r t e r b u c k l e s , and 565 I - u n i t c e n -
('/-)-5 I I I I I
5 I0 15 20 25 ter buckles.
DISTANCE FROM CENTER OF MILL (in) The above c a l c u l a t i o n s show the i m p o r t a n c e of the
Fig. 29--Stand 5 exit strip shape, concave worn backup roils. i n e v i t a b l e r o l l wear in affecting s t r i p shape and that,
with p r o p e r u n d e r s t a n d i n g , c o r r e c t i v e m e a s u r e s a r e
p o s s i b l e as wear conditions change.
WR BUR WRJ I - Units To s u m m a r i z e the e x a m p l e of model application:
Curve Cool Cool Press Center quarter
1. The p r o b l e m was to d e t e r m i n e o p t i m u m r o l l i n g
a Full Center 500 II,745 2350
off conditions for a p a r t i c u l a r alloy which would produce
b Full Full 500 9,565 2400 a c c e p t a b l e s t r i p f l a t n e s s , u s i n g the full power a v a i l -
c Full Full 0 4,]00 1800
d Full Full -500 565 290 able at all s t a n d s of a f i v e - s t a n d cold m i l l .
(deflector) 2. The r e d u c t i o n schedule p r o g r a m e s t a b l i s h e d m a s s
o flow through the m i l l u s i n g all the power a v a i l a b l e at
I each stand. The s a m e p r o g r a m called on the F o r c e -
~-t4
T o r q u e - S l i p Model to solve for t h e s e f a c t o r s at each
[]_
stand.
CE
3. The E n e r g y B a l a n c e Model was then used to c a l -
u3 15 I I I I culate the e n e r g y p a r t i t i o n to the r o l l s and s t r i p at the
i n d i v i d u a l s t a n d s as well as t h e i r t e m p e r a t u r e s .
5 4. The Roll T h e r m a l C a m b e r Model was next used to
Ideal Entry Strip
d e t e r m i n e the t h e r m a l l y induced change ( c a m b e r ) in the
r o l l s h a p e s at each stand. This c o m p u t a t i o n involved
0 all of the p r e v i o u s l y d e t e r m i n e d data as well as the
t h e r m a l c o n d u c t a n c e s for the two r o l l cooling options.
5. The Roll Gap and Strip Shape Model then c a l c u -
Z lated the c o m b i n a t i o n s of i n i t i a l m e c h a n i c a l r o l l shapes
and r o l l - b e n d i n g jack p r e s s u r e s which would yield a c -
CE ceptable s t r i p f l a t n e s s e x i t i n g each of the s t a n d s .
L) 6. The p r a c t i c a l c a s e s of backup r o l l s with concave
el_ Ho o r convex wear w e r e c o m p a r e d with newly ground r o l l s
O2 in the light of t h e i r r e s p e c t i v e effects on s t r i p f l a t n e s s .
The model p r e d i c t e d that a c c e p t a b l e f l a t n e s s could be
u3
a t t a i n e d and the c o m p e n s a t i n g a d j u s t m e n t s that were
-15 I I I I I
5 IO 15 2O 25 r e q u i r e d to b r i n g this about.
DISTANCE FROM CENTER OF MILL (in.) 7. The model yielded a solution to the p a r t i c u l a r
Fig. 30--Stand 5 exit strip shape, convex worn backup rolls. p r o b l e m posed and specified the o p e r a t i n g p a r a m e t e r s
which would be r e q u i r e d .
S i m i l a r a n a l y s e s were made for s e v e r a l other alloys,
s h e a r , and P o i s s o n ' s r a t i o . The m o s t s i g n i f i c a n t effect s t r i p widths, s p e e d s , and r e d u c t i o n p a t t e r n s to a r r i v e
of jack p r e s s u r e was on the work r o l l / b a c k u p r o l l n o r - at r e c o m m e n d a t i o n s for m i l l p r a c t i c e s . Other c a s e s
m a l approach n e a r the end of the backup r o l l b a r r e l . w e r e r u n to study c o l d - s t a r t p r a c t i c e and backup r o l l
Fig. 27 shows the s i g n i f i c a n t c o m p o n e n t s of work r o l l e n d - r e l i e f . Mill t r i a l s u t i l i z i n g the m o d e l p r e d i c t i o n s
d i s p l a c e m e n t s v s width. Shear and P o i s s o n ' s r a t i o will be s t a r t e d as soon as the m i l l i m p r o v e m e n t p r o -
were n e g l i g i b l e in this c a s e . A l a r g e negative shift
g r a m p r e s e n t l y u n d e r way is completed.
in the b e n d i n g d e f l e c t i o n s o c c u r s with the addition of
500 psi jack p r e s s u r e .
MODEL VERIFICATION
Fig. 28 shows the f o r c e d i s t r i b u t i o n s b e t w e e n the
work r o l l and s t r i p and b e t w e e n the work r o l l and b a c k - F o r any r o l l i n g model to have p r a c t i c a l use, its p r e -
up r o l l . Added jack p r e s s u r e is shown to have r e l i e v e d dictive outputs m u s t c o r r e l a t e well with m e a s u r a b l e

2496-VOLUME 5, DECEMBER I974 METALLURGICALTRANSACTIONS

 2~0 /
20
" i /o
L ; --4,-- /
IO ~v Exit Strip O O/ O /
05 220 Work Roll D ~;'~ _ / / ~
0 d:'" '~ 9 ~1
o Bockup Roll Z~ //~j/" /
" /
L.LJ 9 e"
G: k t ~' "* *
o /
0"4 -Io 9 * v o,//
i [
o: zoo e~o~/(~:~'.'<z~'7"
5 4 5 :~ *\.1 g,y . /
PASS
O 1600 fpm u 500 fpm Open Points-Specific Force
o 1000 fpm ~ 500 fpm Closed Points-Specific Torque C~ J- u q /
z~ 800 fpm D 150 fpm r'r'bJI6~ ,q3.~,~/,,~ a
Fig. 31--Comparison of measured and predicted specific force
and torque.

120
Pass I
o Pass 2
Pass 3 i ; , i i i
o Pass
+ Pass
4
5 /" "X~I Banc I 0 I 0 180 200
PREDICTED TEMP, (~
EL
/
CO
E7 /
//(////
~/ //
/ / \ Fig. 33--Comparison of measured and predicted temperatures
for several products at both stands of a two-stand cold mill.

Cooled Zone
rY 140[ ~"
<:~ / j~ /
Strip Width
/ / /e / .11 . . . . . . . . . .
El/
0
LL // /:// 130 - Predicted I

E:3
Iii
F-
o
E3
, f G.: 12o

Ld iii
EE
EL
//// ,

I I
0 I 2 :5 4 5
MEASURED FORWARDSLIP (%)
Fig. 32--Comparison of measured and predicted forward slip.
p r o d u c t i o n m i l l data. Within the t i m e a v a i l a b l e for this
l e c t u r e , I have c o n c e n t r a t e d on the logical d e v e l o p m e n t
of the model and its powerful a n a l y t i c a l c a p a b i l i t i e s .
However, a l a r g e amount of v e r i f i c a t i o n data has b e e n
compiled f r o m e x p e r i m e n t s on l a b o r a t o r y and p r o d u c -
tion m i l l s . A few e x a m p l e s of the v e r i f i c a t i o n a r e given
below.
P r e d i c t i o n s of force, torque, and f o r w a r d slip have
b e e n found to be a c c e p t a b l y a c c u r a t e for r o l l i n g a l u m i -
num. They have b e e n c o n f i r m e d in s e v e r a l different
m i l l s for a v a r i e t y of alloys and t e m p e r s , and with both
oil and w a t e r - b a s e d l u b r i c a n t s . Some c o m p a r i s o n s of
m e a s u r e d and p r e d i c t e d f o r c e and t o r q u e a r e shown in
Fig. 31. F o r w a r d slip c o m p a r i s o n s a r e given in Fig.
32. T h e s e data w e r e obtained f r o m m u l t i p l e p a s s e s on
an i n s t r u m e n t e d s i n g l e - s t a n d m i l l s i m u l a t i n g t a n d e m
mill rolling.
The f r i c t i o n and d e f o r m a t i o n e n e r g y d i s t r i b u t i o n s
p r e d i c t e d b y the model a r e not d i r e c t l y m e a s u r a b l e in
m i l l e x p e r i m e n t s . They a r e v e r i f i e d in p a r t by the fact
that p r e d i c t i o n s of r o l l and s t r i p t e m p e r a t u r e s a r e in
good a g r e e m e n t with e x t e n s i v e e x p e r i m e n t a l v a l u e s .
I 0 , .,,. ,o" i
6 7
r'r" i o o ~
I I I
90 I0 0 I0 20 50
DISTANCE FROMCENTER OF MILL (in.)
Fig. 34--Comparison of measured and predicted thermal
camber, fourth stand of a tandem mill.
Fig. 33 shows the r e s u l t s of one such e x p e r i m e n t . Roll
t h e r m a l c a m b e r checks have also indicated that the
model is f u n c t i o n i n g p r o p e r l y . One check s e l e c t e d at
r a n d o m is shown in Fig. 34; this is f r o m the fourth
stand of a t a n d e m m i l l . The m e a s u r e m e n t s were c o m -
pleted about 5 m i n u t e s after the end of r o l l i n g , which
allowed t i m e for the heat to flow f r o m the c e n t e r t o -
ward the c o o l e r e n d s ; this accounts, in part, for the
lower than p r e d i c t e d t e m p e r a t u r e g r a d i e n t s at the
s t r i p edges.
M e a s u r e d an d p r e d i c t e d exit s t r i p t h i c k n e s s p r o f i l e s ,
like the one shown in Fig. 35, indicate p r o p e r f u n c t i o n -
ing of the Roll Gap and Strip Shape Model. The m e a -
s u r e m e n t s w e r e made in t e s t s on an i n s t r u m e n t e d p r o -
duction m i l l . T h e s e included f o r c e ; power; f o r w a r d
s l i p ; t o r q u e ; e n t r y and exit t e n s i o n s ; t e m p e r a t u r e and

METALLURGICALTRANSACTIONS VOLUME 5, DECEMBER 1974 2497

 can s i m u l a t e the r o l l i n g p r o c e s s e s of c o n c e r n and a l -
"~"
4~20.0 -. C _ -0~ low d e t a i l e d a n a l y s e s of o p e r a t i n g p r o b l e m s .
5. The k e y to o b t a i n i n g r a p i d r e t u r n s f r o m a r e -
s e a r c h effort in this f i e l d l i e s in the a s s e m b l a g e of an
i n t e r d i s c i p l i n a r y r e s e a r c h t e a m and in the continuous
i n v o l v e m e n t of p r o d u c t i o n m a n a g e m e n t e a g e r to t r a n s -
l a t e v e r i f i e d d e v e l o p m e n t s into o p e r a t i o n s .
cO 6. A new m o d e l of cold r o l l i n g h a s b e e n o p t i m i z e d
W
for a l u m i n u m p r o d u c t i o n and is b e i n g i m p l e m e n t e d
along with c h a n g e s in K a i s e r p r o d u c t i o n f a c i l i t i e s .
T The m o d e l is b e l i e v e d to contain c e r t a i n c o n t r i b u t i o n s
to g e n e r a l cold r o l l i n g t h e o r y for a l l m e t a l s .
7. A v e r y f u n d a m e n t a l a p p r o a c h was t a k e n in the
m o d e l d e v e l o p m e n t which m a k e s it a p p l i c a b l e to a
O3 wide r a n g e of c o n d i t i o n s without the m a n y c o n c e r n s
}~ 0.022 ~) that a r i s e when o v e r s i m p l i f i e d c o r r e l a t i o n s a r e used.
8. The m o d e l and the f l e x i b i l i t y of its m a s t e r c o m -
X
LLI [ I Edgeof Strip---.-
t p u t e r p r o g r a m m a k e p o s s i b l e the a n a l y s i s of p r o d u c -
/ /
0 5 I0 15 tion p r o b l e m s , the i d e n t i f i c a t i o n and q u a n t i f i c a t i o n of
DISTANCE FROM CENTER OF MILL (in,) p a r a m e t e r s f o r new m i l l d e s i g n , and the d e s i g n of s y s -
Fig. 35--Comparisonof measured and predicted strip thick- t e m s which w i l l function b e s t f o r a u t o m a t i c c o n t r o l of
ness. m i l l p r o d u c t output.

t h i c k n e s s p r o f i l e s ; c o o l a n t p r e s s u r e s and p a t t e r n s ; and
ACKNOWLEDGMENTS
r o l l t e m p e r a t u r e p r o f i l e s . Due to d i f f i c u l t i e s in m e a -
s u r i n g e x a c t r o l l w e a r , t h e r m a l c a m b e r s , and v a r i a - The program which I have discussed was performed
t i o n s in s t r i p p r o f i l e s u n d e r m i l l c o n d i t i o n s , a d d i t i o n a l under the general management of T. R. Pritchett and
l a b o r a t o r y r o l l i n g e x p e r i m e n t s a r e p l a n n e d to obtain R. T. Myer at the Corporation's Center for Technology,
the m o r e p r e c i s e v e r i f i c a t i o n d a t a t h a t a r e d e s i r e d . Pleasanton, California and in various production mills.
P e r h a p s the m o s t s i g n i f i c a n t v e r i f i c a t i o n to date is Support and encouragement by line management, par-
t h a t the m o d e l h a s s u c c e e d e d in p r e d i c t i n g a c c u r a t e l y ticularly J. H. Williams, Manager, Sheet and Plate Di-
the t y p e and l o c a t i o n of b u c k l e s v i s u a l l y o b s e r v e d ir, vision, and I. R. Davidson, Vice President and General
p r o d u c t i o n m i l l e x p e r i m e n t s . The v e r i f i c a t i o n of c o m - Manager, Fabricated Products Group, have been sin-
m e r c i a l i m p o r t a n c e , of c o u r s e , will c o m e only as the cerely appreciated.
m o d e l is put to u s e in o u r p r o d u c t i o n m i l l s . This is in Thanks are due especially to the following people for
p r o c e s s and e a r l y r e s u l t s a r e e n c o u r a g i n g . their direct participation in the program:
--C. R. St. John chaired the steering committee and
coordinated the efforts of Research, Engineering, Pro-
cess Technology, and the rolling plants.
SUMMARY --D. G. Harrington supervised the model development
In the c o u r s e of t h i s l e c t u r e , I have t r i e d to m a k e work.
the following m a j o r p o i n t s : --Yu-Wen Hsu developed the Force-Torque-Slip Model
1. The r o l l i n g p r o c e s s is of p r i m e i m p o r t a n c e in the and made major contributions in applied mechanics.
w o r l d . I m p r o v e m e n t s will c o m e about as b a s i c c o n - --M. A. Carter applied the SINDAprogram to thermal
c e p t s a r e a p p l i e d to the p r e s e n t t e c h n o l o g y . T h e s e i m - modeling and performed extensive computer program-
p r o v e m e n t s will b e n e f i t p r o d u c t quality, d e c r e a s e p o s t - ming.
r o l l i n g p r o c e s s i n g , and c o n s e r v e m a t e r i a l p r e s e n t l y --W. A. Niethammer developed rolling mill instru-
requiring reprocessing. Accordingly, reduced rolling mentation and worked on thermal modeling.
c o s t s will r e s u l t . --J. D. Sprowl made major contributions to planning,
2. B e c a u s e m a s s i v e i n v e s t m e n t s in e x i s t i n g r o l l i n g conducting and evaluating mill test programs.
m i l l s in m o s t c a s e s p r e c l u d e t h e i r b e i n g s u m m a r i l y --L. J. Whiteley participated in instrumentation de-
r e p l a c e d b y new units, much c a n b e gained b y a p p l y i n g velopment, mill experiments and computer analysis.
i m p r o v e d t e c h n o l o g y in o r d e r to o p t i m i z e m i l l p e r f o r - --Sus Takeda developed the required digital data
mance. system.
3. R o l l i n g e n t a i l s a m o n u m e n t a l l y c o m p l e x a p p l i c a - --W. A. Wong designed and applied the split-Hopkin-
tion of independent and dependent m e c h a n i c a l , t h e r m a l son bar.
and p h y s i c a l p a r a m e t e r s . T h e s e r e l a t i o n s h i p s a r e b e - To all of this fine team, I am deeply grateful.
c o m i n g b e t t e r u n d e r s t o o d and a p p l i e d b y m e a n s of Valuable assistance in the preparation of this lecture
m a t h e m a t i c a l m o d e l s and c o m p u t e r s . was rendered by many, but I must particularlythank
4. Any c o m p a n y u s i n g r o l l i n g m i l l s c a n r e a p m a n y M e s s r s . H a r r i n g t o n , St. John, W. H. Cundiff, G. G e r a r d ,
b e n e f i t s f r o m the u s e of a c o m p u t e r p r o g r a m which W. J. Davidson and M r s . J a n e t Hallett.

2498-VOLUMES,DECEMBER 1974 METALLURGICAL TRANSACTIONS

 APPENDIX A 18. G. T. Van Rooyen and W. A. Backofen: J. Iron Steelblst., London, 1957,
pp. 235-44.
C o n v e r s i o n f r o m E n g l i s h to International S y s t e m Units 1% F. A. R. AI-Salehi, T. C. Firbank, and P R. Lancaster: Int. ,L Mech. ScL, 1973,
E n g l i s h Unit • C o n v e r s i o n Factor = S.I. Unit voi. 15, pp. 693-710.
20. J. Hitchcock: Elastic Deformation of Rolls During Cold Rolling, Roll Neck
Bearings, ASME Research Publication, Appendix I, 1935.
Quantity English Unit Conversion Factor S.I. Unit 21. C. F. Zorowski and A. S. Weinstein: Iron SteelEng. YearBook, 1961, pp.
392-99.
Distance in. 2.54 cm
22. A. H. El-Waziri: Iron SteelEng. YearBook, 1963, pp. 753-59.
nail 2.54 • 10-s cm
23. H. S. Chang: in Friction and Lubrication in Metal Processing, pp. 69-89,
Area sq in. 6.452 sq cm
ASME, N.Y., 1966.
Differentialstrain, in./in. X l0 s 1 cm]cm • l0 s
24. W. L. Roberts: lron Steel Eng. YearBook, 1968, pp. 362-70.
/-units
25. J. D. Gaski, D. R. Lewis, and L. R. Thompson: C1NDA-3G: Chryslerlm-
Speed ft/min (fpm) 5.08 • 10-3 meter/sec (m/s)
pro red Numerical Differencing Analyzer for 3rd Generation Computers,
Weight pound (Ib) 0.4536 kg
Chrysler Corp. Space Div., New Orleans, La., TN-AP-67-287, Oct. 1967.
ton (T) 907.2 kg
26. J. D. Gaski, L. C. Fink, and T. Ishimoto: SINDA: Systems Improved Numeri-
Pressure; stress lb/sq in. (psi) 6.895 • 10s Pascal (Pa)
cal Differencing Analyzer: UsersManual, TRW Systems, Inc., Redondo Beach,
kpsi 6.895 • 106 Pa
Ca., NASA Contract Report 9-8289, Sept. 1970.
Specific force lb/in. 1.7512 Newton/cm (N/cm)
27. S. Cerni, A. S. Weinstein, and C. F. Zorowski: Iron Steel Eng. Year Book,
Specific torque ft-ib/in. 0.5338 Joule/cm (J/cm)
1963, pp. 717-25.
Power hp 745.7 Wall (W)
28. C. F. Peck, J. M. Bonetti, and F. T. Mavis: Iron SteelEng. YearBook, 1954,
Energy hp-h/T 2.96 X 10 s J/kg
pp. 3 8 9 4 0 2 .
Temperature ~ 5/9 (~ + 460) ~
29. D. M_ Parke and J. L. L. Baker: 1ton Steel Eng., 1972, vol. 49, no. 12, pp.
Heat flow Btu/h-in. 0.1154 W/cm
83-88.
Heat transfer Btu/ftLh-~ 5.677 X 10-4 W/cmZ-~
30. F. Seredynski: J. Iron Steellnst., London, 1973, vol. 211, pp. 197-203.
coefficient
31. B. F. Bradley, W. O. Cockett, and D. A. Peel: in Mathematieal Models in
Thermal Btu/h ~ 0.2077 W/~
Metallurgical Process Development, Proceedings of Conference Feb. 1969,
conductance
pp. 79-92, Iron and Steel Institute, London, 1969.
32. R. Dalheimer: Ind. Anz., 1970, vo[. 92, pp. 1731-32.
33. R. J. Fiorentino, et al. Investigation of Possible Advantages of Un'lizing Heat
RE FERENCES Rolls for Hot Rolling Metals, Battelle, Columbus, Ohio, Report No. 809290,
Jan. 1967.
1. T. Sheppard and J. M. Roberts: lnt. Met. Rev., 1973, vol. 18, pp. 1-18. 34. S. I. Steindl and W. B. Rice: Measurement of Temperature in the Roll Gap
2. H. W. O'Connor and A. S. Weinstein: J. Eng. lnd. (Trans. ASME, B), 1972, During CoM Rolling, ASM paper, 1973.
vol. 94, pp. 1113-23. 35. H. tnhaber: J_ Eng. Ind. [Trans. ASME, B}, 1967, vol. 92, pp. 471-77.
3. K. N. Shohet and N. A. Townsend: J. Iron SteelInsL, London, 1971, vol. 209, 36. T. H. Hogshead: Heat Transfer and Temperature Distributions in the Rolling
pp. 769-75. of Metal Strip, Ph.D. thesis, Carnegie Institute of Technology, May 1967.
4. O. C. Sivilotti, W. E. Davies, M. Henze, and O. Dahle: Iron Steel Eng., 1973, 37. H. Becket and B. Konig: WissZ. Tech. Hochsch., Magdeburg, 1970, pp.
vol. 50, no. 6, pp. 83-90. 54145.
5. E. Orowan: Proc. Inst. Mech. Eng., 1943, voh 1590, pp. 140-67. 38. P. I. Polukhin: StalEngl. (USSR), 1963, vol. 9, pp. 712-16.
6. L. W. Koot: in Process Technology, Hoogovens BV Ljmuiden, 1972. 39. J. W. Beeston and W. J. Edwards: in Automation of Tandem Mills, Iron and
7. G. F. Bryant: in Automation of Tandem Mills, Iron and Steel Institute, Lon- Steel Institute, London, 1973.
don, 1973. 40. S. Wilmotte and J. Mignon: Met. Rep. CRM, 1973, no. 34.
8. R. J. Bentz and R. A. Dickinson: Blast Furn. SteelPlant, 1965, vol. 53, pp. 41. H. A. Kuhn and A. S. Weinstein: Z Eng. lnd. (Trans. ASME, B), 1970, vol. 92,
319-24. pp. 453-60.
9. W. L. Roberts: Iron SteelEng. YearBook, 1965, pp. 925-37. 42. K. N. Tong, M. Sadre, and M_ K. Chakko: lron SteelEng. YearBook, 1963,
I0. R. J. Bentz and W. L. Roberts: BlastFurn. SteelPtant, 1970, vol. 58, pp. pp. 339-45.
559-68. 43. K. N. Tong, M. K. Chakko, and J. V. Latorre : Iron Steel Eng. Year Book,
11. A. Nadai: J. Appl. Mech., 1969, vol. 6, pp. A-54-A-62. 1963, pp. 555-66.
12. R. Hilt and L M. Longman: Sheet Metal Ind., 1951, vol. 28, pp. 705-06. 44. Tsu-Tao Loo: Z AppL Mech., I958, vol. 25, no. 1, pp. 122-24.
13. R. Hill: Proc. Inst. Mech. Eng., 1950, voL I63, pp. 135-40.
14. R. B. Sims: J. Iron Steellnst., London, 1954, vol. 178, pp. 19-34.
15. D. Jortner, J. F. Osterle, and C. F. Zorowski: Iron Steel Eng. Year Book, Note added in proof: At press time, the mill start-up using the exact model
1958, pp. 403-11. instructions described in the section "Analysis of a Tandem Mill Problem" was in
16. P. Cosse and M. Economopoulos: C.N.R.M. Met. Rep., 1968, no. 17, pp. 15-32. process. In the first week of production, the tandem mill had achieved two-thirds
17. Yuji Matsura and Mitsugu Motomura: Rep. Cast. Res. Lab., Waseda Univ., of the targeted power usage and speed. Full target performance with excellent strip
1967, no. 18. flatness is anticipated.

METALLURGICAL TRANSACTIONS V O L U M E 5, D E C E M B E R 1 9 7 4 - 2 4 9 9