MAE 212: SLAB ANALYSIS FOR FLAT ROLLING

N. Zabaras, Spring 2000

Figure 1: Schematic of flat rolling showing the neutral point, N .

X
Fx = 0 ) (x + dx ) (h + dh) x h
 (2pRd) cos
+ 2pRd sin (1)

= entry
+ = exit

| {z x} x h  2pRd cos + 2pRd sin = 0 )

x h + x dh + hdx + dhd
zero
d(x h)
d = 2pR ( sin  cos) 37
sin   5 )
cos  1
Small angles:

d (x h)
= 2pR (   ) (2)
d
1
 Figure 2: Stresses on an element in rolling: (a) entry zone and (b) exit zone.

For small angles take z ' p and for plane strain (y = 0) )
x + p = p2 Y (Y = Yield Stress) (3)
3
| {z }
true anywhere inside the deformation zone

h changes with  as follows:

Figure 3: Approximation of h in terms of .


h = hf + 2 (R) sin
2

= hf + 2 (R)
2
2
= hf + R (4)

2
We assume that as the material advances inside the deformation zone, its hardening behavior is
such that: Y h = constant (so as h decreases, Y increases such that the product Y h remains
constant!!! A ridiculous assumption that however is better than assuming that Y is constant inside
the deformation zone!).

Returning to the equilibrium equation with the above assumption, we can write:

 
d (x h) d p23 Y p h
d
=
d
=
Y h) d (ph)
p2 d (d d
| 3 {z }
  zero
d (ph) d p Y1 Y h d (p=Y )
= = = Yh
|{z} (5)
d d d const

Finally:
 
p
d Y
Yh = 2 pR (   ) )
d  
d Yp 
p = 2 R d )
Y h
d( Yp )
p
Y
=2 R hf +R2 d (6)

Let us integrate the above equation in the entry region from  =  to a general angle . Similar
calculation can be applied to the exit region.

 
Z d p Z +
Y
=2 R d ) (7)
entry p
Y entry hf + R2
  
p p
j h R 2  + ln h + R2 
Y0 entry s
ln ln = ln f + f
Y s 1
+ 2R q
1
@tan 1 R  tan 1 R A (8)
hf R h h

Note that in the last calculation we used the following integral formula:
Z dx bx
a2 + b2 x2
1
=
ab
arctan
a
; (arctan  tan 1) (9)

3
At the entry region using the yield condition, one can write the following:

2Y    
p √
3
− σx 2 σb 2 σb
|entry = |entry = √ − = √ 1−  (10)
Y Y 3 Yentry 3 Yentry


where Yentry = √2 Yentry .
3

So returning to equation (8), we can write:

 
p 2 σb
−ln + ln √ 1 − 
Y 3 Yentry
 h
  ho

     
= −ln  2  2
hf + Rφ  + ln hf + Rα 

   
1 −1 R R 
+ 2Rµ  tan φ − tan−1 α (11)
hf R h h

Define:
  
R R
H = 2 tan−1 φ
hf hf
  
entry
R R  
Ho = 2 tan−1  α (12)
hf hf

Equation (11) is now simplified as:

p
ho
−ln  Y = µ (H − Ho ) ⇒
√2 1−

σb
h
3 Yentry
p

ho
−ln  Y = µ (H − Ho )
h 1−

σb
Yentry
p
h
Y
o
ln  = µ (Ho − H) (13)
h 1−

σb
Yentry

Finally, the following pressure distribution is derived in the entry region:

 
p σb h µ(Ho −H)

= 1−  e (14)
Y Yentry ho

4
where H and Ho are given by equation (12).

To derive the corresponding equation in the exit region, you can repeat the above calculations
by integrating equation (6) (with the bottom sign in ±) from angle φ to angle 0 (exit).

It is also possible to derive the distribution of p at the exit using equation (14) with some
changes!  
 
here ho → hf , Yentry → Yexit
(15)
Ho → 0 (because α = φat the exit = 0)

 
p σf h µH
= 1 − 
e (16)
Y Yexit hf

Equations (14) and (16) define the complete pressure distribution in the deformation zone.

Calcuation of the Neutral Point

Equate the two pressure expressions from equations (14) and (16):
   
σb h µ(Ho −H) σf h µH
1− 
e = 1−  e (17)
Yentry ho Yexit hf

1− σb


Yentry hf
µ(2H−Ho )
⇒e = σ (18)
1 − Y
f ho
exit

Simplifying for the case σb = σf = 0 leads to:

 
1 1 ho
Hn = Ho − ln (19)
2 µ hf

  
R R
2 tan−1 φn = Hn ⇒ (20)
hf hf

 
hf hf Hn
φn = R
tan R 2
(21)