Applied Mechanics and Materials Vols 130-134 (2012) pp 139-142 Online: 2011-10-27

© (2012) Trans Tech Publications, Switzerland

doi:10.4028/www.scientific.net/AMM.130-134.139

Stress-strain Analysis of Back-up Roll with Roll-sleeve

Zhongying Zhuaa and Dengyue Sunbb *

National Engineering technology research center of cold rolling strip equipment and technology,
Yanshan University, Qinhuangdao, Hebei Province 066004, P.R.China
a
zzy456321@126.com.cn, bsdy@ysu.edu.cn

Corresponding author: Dengyue Sun, male, Professor; Research direction: Rolling Theory and
Process Simulation. Tel.: 13582403079; First author: Zhongying Zhu, male, Master graduate
student; Tel.: 15227273256.

Keywords: Back-up roll; Roll sleeve; Stress-strain analysis; Magnitude of Interference.

Abstract. The back-up roll with roll-sleeve was studied and simulated using the finite element
analysis software Abaqus in this paper. The stress-strain field of back-up roll with different
roll-sleeve thickness and different magnitude of interference were compared because these two
parameters are of importance for us to guide the application of roll with sleeve.

Introduction
The back-up roll [1] with roll-sleeve is a branch of the family of forged back-up rolls. Its basic
method is to fabricate roll core using good ductile material, to make roll sleeve using high hardness
and high wear-resistant material. Then these two parts were assembled together by interference,
composing of a new roll. This kind of roll, with good mechanical properties [2], is difficult to break
because it has good toughness, to wear because it has high hardness and wear resistance. And
because the roll core can be repetitive-used, so we could save a lot of costs on it. The application
and development of the back-up roll have an important effect on preventing break roll, reducing roll
consumption, increasing operating rate and reducing the cost of rolling.

Back-up roll finite element analysis

Roll material selection. The choice of roll material is closely related with the roll working
characteristics and the damaging form.
Back-up roll plays a supporting role to the work roll, so it is required to have good stiffness; It
always contacts with work roll, resulting in hardening, so that the micro-cracks produce at the
bottom of the skin when the roll created yield because of overload, which requires the roll has a
high contact fatigue strength, good resistance to stress and crack growth.
The roll sleeve and roll core material as follows: roll sleeve material: 4Cr5MoV1Si, roll core
material: 35CrMo. The properties of these materials in reference [3].
The choice of magnitude of interference. Interference fit is widely used in engineering, especially
in some occasions of transmitting high moment of torque. And in order to ensure the reliability of
fitting, the key is to reasonably determine the magnitude of interference and select the appropriate
fitting-in between roll-sleeve and roll core.
Conventional design method mainly based on analogy pattern, the magnitude of interference of
the roll with roll-sleeve is generally elected 0.03%~0.1%, but in different conditions, varies
considerably.
The simplified model of back-up roll and work roll. For roll that the axial length much larger
than contact area, we can simplify it to two-dimensional plane strain model, which not only greatly
reduces the demands on the computer configuration but also the computing time. And the results are
also reasonable [4]. The simplified model of roll is shown as Fig.1.

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140 Mechanical and Electronics Engineering III

Fig.1 Simplified model of roll Fig.2 The meshing results of roll model
Finite element modeling.
Boundary Conditions. Because the entity units in finite element have not rotational degrees of
freedom, we should set a reference point in the roll center coupling regional nodes to define the
rotation [5].Firstly, setting restraints on the reference points of the two parts including the
translation (U1, U2) and rotation (UR3) degrees of freedom. Then adding the pressure in the U2
direction to the reference point of the roll core and releasing the point freedom in U2. In addition,
adding rotating radian in work roll while decontrolling of the rotation (UR3) degrees of freedom of
back-up roll and work roll, so that the work roll can drive back-up roll running by means of the
friction between them to simulate the real rolling process.
Meshing and Calculation. Roll sleeve, outer periphery of work roll and roll core are meshed
with quad element shape, sweep grid, the other part is quad-dominated shape, sweep grid. Element
type is CPE4I (4-node bilinear plane strain quadrilateral, incompatible modes) [6]. The meshing
result of roll model is shown in Fig.2.
Results Comparison.
In this section two types of different rolling model (different roll-sleeve thickness and different
magnitude of interference) will be analyzed.
Table1 The parameters of model with different roll-sleeve thickness
Parameter Sleeve Sleeve external Work roll Magnitude of Roll pressure
thickness[mm] diameter[mm] diameter[mm] interference[mm] [t/mm]
Magnitude 100 150 200 2000 1000 2 1

(1)The results analyzing for different roll-sleeve thickness

Equivalent Stress (Pa)

8.0E+08 1.2E+09
thickness100 thickness100mm
7.0E+08 mm 1.0E+09
Equivalent Stress (Pa)

thickness150 thickness150mm
6.0E+08 mm 8.0E+08
thickness200mm
thickness200 6.0E+08
5.0E+08 mm
4.0E+08
4.0E+08
2.0E+08
3.0E+08
0.0E+00
2.0E+08 0 20 40 60 80 100 120 140 160 180 200
2.7 2.75 2.8 2.85 2.9 2.95 3 Radial distance of the roll-sleeve (mm)
Rolling times (s)

Fig.3 Equivalent stress distribution of one Fig.4 Equivalent stress distribution of points
surface point of the roll-sleeve along the radial direction of the roll-sleeve

Fig.3 shows equivalent stress distribution of one surface point of the roll-sleeve for different
sleeve thickness. The surface stress remains the size of initial stress in the non-rolling area, while
once that point rolls into the contact area, the value of stress quickly reaches 750MPa or so. When
sleeve thickness gets larger, the maximum stress decreases but varies little.
Fig.4 is equivalent stress distribution of points along the radial direction of the roll-sleeve in the
contact area. The picture above shows the maximum stress value 1050MPa located in area
distancing surface 3~6mm. Then the stress reduces rapidly along the radial direction. When it
reaches about 60mm distancing the surface, the curve has become more gently, slowly rising in
radial direction.
Fig.5 is the logarithmic strain distribution of points along the radial direction of the roll-sleeve in
the contact area. The strain curve keeps the same trend with the stress curve in Fig.4.
 Applied Mechanics and Materials Vols. 130-134 141

Fig.6 is the logarithmic strain distribution of one point of the contact surface between the roll-
sleeve and roll-core. Under the same magnitude of interference, logarithmic strain at the same
position of roll-sleeve inner surface produces large gap. The sleeve is thicker, the value of
logarithmic strain is lower, indicating that the rolling force get little impact on the internal surface,
which will be better to the life of roll. Therefore, the thicker the better for the sleeve under the
strength and processing permitting.
0.0035 0.0026

Logarithmic strain
Logarithmic strain

0.003 thickness100mm
0.0025
0.0025 thickness150mm
0.002 0.0024 thickness200mm
0.0015 thickness100mm
0.0023
0.001 thickness150mm
0.0022
0.0005 thickness200mm
0 0.0021
0 20 40 60 80 100 120 140 160 180 200 1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 3
Radial distance of the roll-sleeve (mm) Rolling times(s)

Fig.5 Logarithmic strain distribution of points Fig.6 Logarithmic strain distribution of one
along the radial direction of the roll-sleeve in point of the contact surface between the
the contact area roll-sleeve and roll-core
Table2 The parameters of model with different magnitude of interference
Parameter Sleeve Sleeve external Work roll Magnitude of Rolling
thickness[mm] diameter[mm] diameter[mm] interference[mm] pressure[t/mm]
Magnitude 200 2000 1000 1 1.5 2 1

(2) The results analyzing for different magnitude of interference

Equivalent stress (Pa)

9.0E+08 1.2E+09
interference interference 1.0mm
8.0E+08
Equivalent stress (Pa)

1.0mm 1.0E+09
7.0E+08 interference interference 1.5mm
6.0E+08 1.5mm 8.0E+08
interference interference 2.0mm
5.0E+08 6.0E+08
4.0E+08 2.0mm
4.0E+08
3.0E+08
2.0E+08
2.0E+08
1.0E+08 0.0E+00
0.0E+00 0 20 40 60 80 100 120 140 160 180 200
1.9 1.93 1.96 1.99 2.02 2.05 2.08 2.11 2.14 2.17 2.2 Raidal distance of roll-sleeve (mm)
Rolling time (s)

Fig.7 Equivalent stress distribution of one Fig.8 Equivalent stress distribution of points
surface point of the roll-sleeve along the radial direction of the roll-sleeve

Fig.7 is equivalent stress distribution of one surface point of the roll-sleeve for different
magnitude of interference. The surface stress remains the size of initial stress in the non-rolling
area, while once that point rolls into the contact area, the value of stress quickly reaches peak point.
For magnitude of interference 1.0mm, the stress rapidly reaches 400MPa, for magnitude of
interference 1.5mm, the value rapidly reaches 750MPa, when magnitude of interference is 2.0mm,
the value rapidly reaches 800MPa. The greater magnitude of interference is, the maximum stress
will be.
Fig.8 is Equivalent stress distribution of points along the radial direction of the roll-sleeve in the
contact area. The picture above shows the maximum stress value located in area distancing surface
3~6mm. Then the stress reduces rapidly along the radial direction. When it reaches about 60mm
distancing the surface, the curve has become more gently, slowly rising in radial direction. We can
know that from the curve the greater the magnitude of interference is, the maximum stress will be.
For magnitude of interference of 1.0mm, the maximum stress is 850MPa or so; for magnitude of
interference of 1.5mm, the maximum stress is 860MPa or so; for magnitude of interference of
2.0mm, the stress reaches a maximum value 1050MPa. This shows that the magnitude of
interference can not be too large, or the stress will vary severely in the rolling process.
142 Mechanical and Electronics Engineering III

Conclusion
1) Under the same magnitude of interference, the inner surface stress changes little for the rolls
with different sleeve thickness. The thicker sleeve remains lower stress at the surface of roll.
However, under the same sleeve thickness, the equivalent stress increases in proportion following
the magnitude of interference increasing.
2) Known from fig.3&4, the sleeve thickness takes little influence on the roll surface and inner
stress perk; while fig.7&8 shows that the stress has a large growth on the basis of initial stress
following the magnitude of interference increasing. This results the stress distancing the surface
3~6mm reaches a maximum value, which will be bad for fatigue life of roll. Therefore, under
ensuring transferring enough torque circumstance, the magnitude of interference should be keep
lower. This can ensure that the roll stress values remain low in the rolling process.
3) The sleeve is thicker, logarithmic strain of the internal surface varies little, which is beneficial
for the roll life. Therefore, under the strength and processing permitting, the roll sleeve should be
selected more thickly, which can also reserve sufficient value for the roll grinding.

Acknowledgement
Sustentation fund: Natural science foundation of Hebei (E2010001155)

References
[1] D.Y.Sun: China Utility Patent 200720138493.0 (2009)
[2] Q.Dong: Cfhi Technology, (2008) No.1, P26-27(in Chinese)
[3] H.M.Lu and Y.Y.Chen: Mechanical Engineering Material Properties Data Manual (China
Machine Press, China 1994)
[4] Iquchi, Takaaki, Yarita and Ikuo: ISIJ International, 1991,31(6):560~565
[5] D.Y.Sun, Z.H.Wei, H.F.Zhou and S.M.Xu, Applied Mechanics and Materials, v16-19, p
1203-1207(2009), e-Engineering and Digital Enterprise Technology VII
[6] D.Y.Sun, Y.F.Zhang and X.W.Zha, in Applied Mechanics and Materials, edited by H.H.Tan /
Trans tech publications, China: (2010) v37-38, p 166-170
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Press, China 1994)
Mechanical and Electronics Engineering III
10.4028/www.scientific.net/AMM.130-134

Stress-Strain Analysis of Back-up Roll with Roll-Sleeve

10.4028/www.scientific.net/AMM.130-134.139