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JOURNAL OF IRON AND STEEL RESEARCH, INTERNATIONAL. 2012, 19(8): 06-11

Modeling of Stress Distribution During Strip Coiling Process

WANG Yong-qin, LI Li, YAN Xing-chun, LUO Yuan-xin, WU Liang
(The State Key Laboratory of Mechanical Transmission, Chongqing University, Chongqing 400030, China)

Abstract: Many strip materials are coiled after rolling process. T h e stresses are imposed on the material wound on
the automatically controlled collapse mandrel under the coiling tension. T h e coiling process can be described by three
typical cases: winding without automatic adjustment, winding with automatic adjustment and after mandrel removal.
A new model of equations for predicting the stresses during the strip coiling process is built by consideration of the
three cases respectively. By solving the equations of different typical cases, the radial stresses and tangential stress of
the layers of coil can be calculated. Also, the coiling parameters, such as strip thickness, coiling tension and necking
critical pressure, affecting the coil performance are investigated. It is believed that the present model can be used for
design and control of the automatically controlled collapse mandrel.
Key words: automatically controlled collapse mandrel; coiling process; critical pressure; radial stress; tangential stress

For the conversion of transportation and handling
thin sheet metal, the coiler has been widely used in
the steel making company. T h e productivity of pro-
duction line is directly affected by the efficiency of
the coiler, especially for the continuous production
line. Compared to the traditional mandrel, the auto-
matically controlled collapse mandrel has two advan-
tages: it is easy to remove the mandrel, and the ra-
dial stress can be controlled. Therefore, it has been
widely used in the industry.
T h e radial stress applied on the mandrel is the
key parameter in control of the automatically controlled
collapse system. T h e tension cannot stand when the
radial stress is too weak. It is difficult to remove the
mandrel even the mandrel is destroyed for high ra-
dial stress. How to determine the critical radial
stress has been one of the major problems in the
control of the coiling process, especially for coiling
the ultra-high strength steel. Based on the working
principle, the coiler mandrel can be divided into two
types: solid mandrel and automatically controlled
collapse mandrel. T h e main difference between the
two types of mandrel is that the radial stress of the
former will monotonically increase when the wound
layers increase, while radial stress of the latter can
be limited below the critical pressure in the winding
process. From literature survey, some researchers have
dedicated efforts on modeling of the coiling process. In
theoretical models for predicting the radial stress"' , the
coil and mandrel are considered as elastic thick cylin-
ders, and it can be simplified as twedimensional strain
case. Most of these models were developed based on
the Inglis' model by the consideration of anisotropy
of the material and deformations between layers.
However, these models cannot be used for calculat-
ing the radial stress of automatically controlled col-
lapse mandrel. T h e design of automatically con-
trolled mandrel is based on the experience which will
limit the performance of designed system.
1 Review of Existing Model
Because of the widespread use of the coiling
process and the possibility of material damage due to
stresses induced by winding, there have been many
studies of the radial and tangential stresses on the
mandrel and the effects of parameters such as the
coiling tension, thickness of strip, and the friction
between wraps.
T h e working principle of the automatically con-
trolled collapse mandrel is shown in Fig. 1. When
the radial stress increases to the critical pressure,
the axial force of the sector blocks applied on the
pyramid shaft is larger than that applied from the
hydro-cylinder. Then the pyramid axis moves and
mandrel starts reducing, and the radial stress falls sub-
sequently, so that the pyramid axis gets balance at a

Biography:WANG Yong-qin(lBBl-), Male, Professor; E-mail: wyq@cqu. edu. cni Received Date: June 21, 2011
Issue 8 Modeling of Stress Distribution During Strip Coiling Process
P
t .t. 1. + t .t.
1-Sector block; 2-Pyramid shaft; 3-Hydraulic
Fig. 1 Working principle of automatically
controlled collapse mandrel
new position. This form repeats itself till the winding
up. T h a t is to say the largest radial stress is equal t o
the critical pressure.
One of the most representative models is the In-
glis’s model“] in which the coiled strip and the man-
drel were considered as elastic thick-walled cylin-
ders. T h e radial stress on the internal surface of the
outer layer, p, , is induced by the coiling tension.
This radial pressure will indirectly induce the radial
stress increment, Api , on outer surface of the man-
drel through the wound layers. T h e radial stress of
the mandrel is accumulated by the effects of each
wound layers. T h e model is deduced by Inglis:
where, no is the tensile stress; r1 is the equivalent
inside radius of mandrel; r2 is the outside radius of
mandrel; and R, is the largest radius of the strip coil.
Several other mathematical models were presen-
ted t o study the radial and tangential s t r e s ~ e s ~ ~ - ~ ]ness
However, these models have its disadvantages re-
spectively. T h e Inglis‘ and Bai’s modelsC6]are only
applicable to calculate the radial stress of mandrel
without automatically controlled collapse. Some of
experiential coefficients are introduced in Lian‘ sCs1
model that it cannot well predict the radial stress for
a general case. In Cong’s modelc4], the tangential
stress was not precisely considered and the variation
of strip thickness is neglected. ZHOU Guo-yingCsl
did not consider the change of tension stress in the
coil, and the automatically controlled collapse he men-
tioned refers to the radius elastic deformation caused by
the pressure but not the initiative necking of mandrel.
With the development of computer technology,
finite element method ( F E M ) is widely used for
simulating the coiling process. Ref. [7] conducted a
numerical simulation for the winding process in coi-
ling using MARC, and a new formula for predicting
the radial stress on the mandrel by analyzing and fit-
ting simulation results. However, it is resource con-
- 7 .
suming for simulation of the overall process. The
simulation only predicts 10 layers which is far less
than the actual overall layers. Ref. [8] regards the
reeled coil and the mandrel as a thick-walled cylinder
t o reel the next layer on it. However, both of them
do not consider the case of the automatically con-
trolled collapse. Therefore, a new model is desired
cylinder.
for predicting the automatically controlled collapse
in the coiling process.
2 A New Model for Computing Radial Stress
2.1 Problem statement
T h e problem is t o analyze the stress and de-
formation in a coil that has been wound on a mandrel
and removed from the mandrel. This problem will
be broken down into four steps: calculation of the
stress in the first layer as it is wound, stresses in
the growing coil before the controlled collapse, after
the controlled collapse, and deformation of the
change in stress caused by the mandrel removal.
Here it is assumed that the coiled material is linearly
elastic, isotropic and the coil is in an axisymmetric
state of stress, and there is no slipping between the
layers in the coil.
2.2 Proposed model
1) Step 1
As shown in Fig. 2 , ro stands for the initial out-
er radius of mandrel, effective inner radius is rd, and
the first layer initial thickness is equal to coil thick-
. h , with initial radius of r , . After the first layer
is wound, the inner and external radius of the layer
change to rll and r Z 1 , and the radial stress on the
mandrel is pIl.
After fimt. layer wound
Fig. 2 Deformation and stress in first layer
 . 8 * Journal of Iron and Steel Research, International
~
The tangential stress in the first layer is equal
to the coiling tension stress, taken as a. , that is
m
1 the surface of ith layer imposed on the initial condi-
a0 =Bjj (2)
where, T is tension of the strip; and B is the width
of the strip.
This process could be considered as a plane strain
problem, and there are four unknown quantities
which are r1 , rll , r l z , p l l . The stressstrain formula
of elastic mechanics is used for the thick-walled cyl-
inder, and the equations could be established as
p11 rl =hao
where, E is Young's module of the strip; and U
the Poisson ratio of the strip.
, is
By solving the above equations, the radial and
tangential stresses could be figured out.
2) Step 2
As shown in Fig. 3 , ri is the initial inner radius
of the ith layer, layers denote with r l i , r Z i ,* * - , rii so
are the radial stress as p l i , p Z i, **. , p f , and the out-
ermost radius in the outer surface is rs+l.So ( 2 i i - 2 )
equations should be established to solve these ( 2 i + 2 )
variables.
The tangential stress in the ith layer is equal to
that caused by coiling tension, and that could be de-
scribed as
p u r i=hao (4)
After ithlayer wound
Fig. 3 Alteration of radios and stresses after
ith layer is wound
Val. 19
The deformation of the ith layer is the same de-
formation caused by the radial pressure existing on
tion of ith layer, and that could be described as
(6)
The change of quantity in the external radius is
equal to the variable quantity caused by the pressure
imposed on the initial outer surface of mandrel.
That could be described as
The change of the inner and external radius of
j t h layer is equal to the deformation caused by the
radial pressure on the j t h layer imposed on the ini-
tial condition of j t h layer. That could be described as
1
+
r". .-+. = E[(rj+h)'-r$] { C P j i f . 3 - P j + l . i (rj
h)2](1-~L)rj-rj(rj+h)2(pj+l,i--p,)
(1+,>) (8)
pJ+~.,(rJ+h)21(l-t()(rJ+h)-~~rJ+
h ) ( p j + 1 -pjt 1( 1+ ~ u > } (9)
Solving the equations established by the bound-
ary condition discussed hereinbefore, the radius of
layers and the radial stresses on the mandrel and be-
tween layers could be calculated. The tangential
stresses could be computed by the radial pressure
imposed on the initial condition of layers.
3 ) Step 3
Ref. [9] deems that the radial stress gets to the
critical pressure and remains at this point, and when
the tangential stress reaches certain value the inner
strip will be instable and shrinking. When the radial
stresses in the mandrel gradually increase to the crit-
ical pressure, the mandrel begins to reduce. This re-
mains the radial pressure at the settled critical level.
Means p l t is equal to 9,. It is assumed that there is
no slipping between the mandrel and coil. The clear-
ance is caused by initiative reducing balances
through elastic deformation of layers.
Different equations need to be established to de-
scribe the condition after controlled collapse. Since
the mandrel is in conjunction with the coil only by
the constant radial pressure, equations could be es-
tablished without referencing of mandrel but only
coil. Comparing with the equations of second step,
equation pl, = p o can be used to replace Eqn. ( 7 )
Issue 8 Modeling of Stress Distribution During Strip Coiling Process ' 9 '
~

while other equations remained. 2.3 Simulation method and verification

4) Step 4
When the mandrel is removed the inner radius
of the coil becomes a free surface and the radial
stress turns to zero. As shown in Fig. 4 , p,,, and r,
are the radial stresses and radius on the inner surface
of layer j . T h e external radius and the pressure of
the outermost are T , , + ~ , "and P,+~,,,.
T h e inner and outside surfaces are two free sur-
faces, on which the radial stresses are zero. T h e in-
ner radius of the initial condition of j t h layer r, is
calculated in the previous steps. For j increase from
1 t o n , the equations can be established as
Pn+l,n=o
Pl,. =o
C H A N G Tie-zhuc"' proposed an iterative flow
chart t o predict the stresses. However, it's not ap-
plicable for computing the stress distribution during
the coiling process. Here, the four steps of coiling
aforementioned are used to solve the problem. Be-
fore the next layer is wound, the radial pressure on
the mandrel should be compared with the critical
pressure. If the radial pressure is less than the criti-
cal pressure, the stresses could be calculated by sol-
ving the equations in the second step. Otherwise,
the model of the third step is used when the mandrel
begins to collapse. The flow chart is shown in Fig. 5.

Radial pressure on
i=i+l, w e model
mandrel has inrretlsedto
before auto-necking
critical pressure*?
1 of mandrel to ralnilate
- (I; f h ) = { CP,d - r,, m. ...,r,,, PU. ...,pis
7-]+1,"
-.,"I

+
E [ ( r ,+h>'
p,+1,.~r,+h~21~1-~~~r,+h~-~~rl+h~
( P , + l , n -PI.) ( 1 + p ) 1 auto-necking of mandrel to
By solving these equations, the radial stresses calculate r,, n, ..,
r,,, PZI, ...,fi8

and tangential stresses could be obtained.

End of coil?

removal to calculate
a,..., ti,, p2h P#*

Fig. 5 Flow chart of simulation process

In order t o verify the model, an example should

be studied and compared t o the others models.
However, the others models are not applicable for
the automatically controlled collapse mandrel. For
ease comparison, the mandrel is considered as with-
out automatically control system for this example.
T h e process parameters are as follows: T=100 k N ,
After mandrel removal
h=2 m m , B=1500 mm, r l = 1 4 4 mm, r0=254 mm,
E=21OOO MPa, p=O. 3 , m=27.3 t.
Fig. 4 Illustration of coil unloading The results of these models are given in Table 1. It

Table 1 Comparison of results calculated by different formulas MPa

~~ ~~

Formula Inglis Mapam T~TMKOB Zhou Cong Lian Patrick Author

Radial stress 32. 03 45.19 20.46 26.01 33.54 30.52 31.58 32.14

is noted that the radial stress vanishes at the outer on the comparison, the results of the model are close
radius and reaches a maximum at the mandrel. Based to the others results.
 10 Journal of Iron and Steel Research, International Vol. 19

sure is reached. It remains at the critical pressure and

3 Effects of Coiling Parameters
1) Effect of coiling tension
With the parameters in Table 1, there are vari-
ous coiling tensions, 80, 100 and 120 kN. The critical
pressure is setting on 10 MPa. The result in Fig. 6
shows that the radial stress on the mandrel increases
as the coiling process goes on until1 the critical pres-
then vanishes after mandrel removal. T h e tangential
stress in the inner layer changes from tensile stress to
compressive stress. Moreover, Fig. 6 (c) shows the re-
distribution of the radial and tangential stresses after the
mandrel removal. It indicates that the tangential stress is
rather sensitive to the coiling tension. However, the ra-
dial stress is insensitive to the coiling tension.

50 40
20
0 0
-20 -20
-40 -40
m -50
-60 -60
100 kN
-80
120 kN
-100 -100 -100
o w 150 260 350 0 50 150 250 350 0 50 150 260 350
Number of layer

(a) Stresses in first layer; (b) Stresses distributions at end of coiling; (c) Stresses distributions after removal of mandrel.
Fig. 6 Stress distributions affected by coiling tension

2) Critical pressure increasing of critical pressure and leads to a later shrink-

Using the same paremeters in Table 1, the crit-
ical pressure is set on 3. 8 , 7 and 10 MPa with coi-
ling tension of 100 kN. T h e simulation results are
shown in Fig. 7.
It shows that the tangential stress is reducing with
ing after reeling and discharging. Contrarily, the radial
stresses are not related to the critical pressure.
3) Strip thickness
Using the same parameters in Table 1, the strip
thickness are 1, 1. 5 and 2 mm. Fig. 8 shows the effects

!W7
40

-20
-40
I
I
-40 10 MPa
-80
1:PMPa , 3.8 MPa
-100 3.8MPa , -120 I
060 150 250 350 0 50 160 250 360

(a> Critical pressure @)

A 10MPa
-rfi - rn 7MPa
3.8 MPa
-
Issue 8 Modeling of Stress Distribution During Strip Coiling Process
of the thickness of the strip on the radial and tan-
gential stress distributions. From the results, the
tangential stresses increase for the large thickness
strip while the radial stress is slightly reduced.
4 Application
T h e strip will be rolled from the thickness of
2. 75 t o 0. 5 mm on the 1250 mm cold rolling mill,
3 -60
-80 Tangential
-100
-120
0 400 800 120
( a ) Stress in first layer; ( b ) Stresses distributions at end of coiling;
5 Conclusions
A new method has been developed for predic-
ting the stresses distribution during the strip coiling
process. I t takes into account the thickness varia-
tion of the strip and the automatically controlled
collapse system. Form literature survey by the au-
thors, this investigation is the first t o study the
stress and deformation considering the winding, au-
tomatically controlled collapse and after the mandrel
removal. From this study, it can be concluded that
the coiling tension, the critical pressure and thick-
ness of the strip affect the distributions of the radial
and tangential stresses. It is believed that the pro-
posed method will provide a new method for further
understanding of the stresses distribution and will
help t o design the automatically controlled collapse
system.
As the critical pressure is an important parame-
ter for the design of the mandrel, the future work is
t o determine a reasonable critical pressure and ana-
lyze the factors which cause the collapse of coil by
using FEM.
11
and then be wound on a mandrel with diameter of
610 mm until the diameter of the coil reaches 1730
mm. This actual value for predicting the radial and
tangential stresses is used. Fig. 9 shows the simula-
tion result of the actual situation, and the effect of
reducing the coiling tension is t o reduce the magni-
tude of the tangential stress about l o % , which is
close to the actual condition.
40
0
I"' T a n g e n t i a l l
-40
-no
-120 I ,120
0 400 800 12c 0 400 800 120
Number of layer
(c) Stresses distributions after removal of mandrel.
Fig. 9 Stresses distribution
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