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# Instructional Design Document

STAM Interactive Solutions

### Change Log (as per the minutes pdf)‏

 Changes Suggested by Prof. Ramesh Singh Changes reflected on slide no. 1 Start with photo of “real” roll, voiceover to outline the process Slide 5 – Also refer to the notes section 2 Follow with schematic diagram listing process parameters (slide 15 of lecture notes at Slides 6, 7, 8 & 9– Also refer to the notes section me.iitb.ac.in/~ramesh/me649/rolling.pdf)‏ Show pressure distribution on the schematic (free body diagram / stresses and forces)‏ Introduce neutral point 3 Voiceover to introduce objective of instruction – feasibility for reduction / power Slide 4 – Text & Voice over changed 4 Interactivity / animation – · Fix roll radius, back height and rotational speed of roll · Enter hi and obtain maximum permissible hf · Also show power required (using slides 35, 36, 55 and 56 of above cited lecture notes)‏ · Allow switch between 3 values for m: low, high and medium (use 0.1, 0.2 and 0.4)‏ · Assume steel properties (perfectly plastic)‏ Slide10 - Also refer to the notes section 5 References Slide 11 · Don’t cite the wikipedia · Add reference books as suggested 6 Modify quiz question 1 - Spelling: “affect” vs. “effect” Modify quiz question 4 - ”All of above” should be the correct answer Slide 12 & 15

Advanced Manufacturing Process I & II

## Rolling Process

### This demo illustrates the procedure for a 2-high rolling mill. Calculation of the maximum reduction that can be achieved and the power required to drive the rolling mill will be explained.

Advanced Manufacturing Process I & II

## Rolling Process

### Introduction

Rolling:

Is the process of plastically deforming metal by passing it between rolls Is widely used to convert steel ingots into blooms, billets, and slabs, and subsequently into plates, sheets and strips

Provides high throughput Provides good control over the dimensions of the finished product

In Hot Rolling:

Metal is rolled at a temperature above its recrystallization temperature Higher reduction in the cross-section is achieved

In Cold Rolling:

Metal is rolled at a temperature below its recrystallization temperature Better strength and control of dimensions are achieved

Advanced Manufacturing Process I & II

## Rolling Process

### Rolling Process

Rolls transfer energy to the strip through friction. As the strip is dragged by the rolls into the gap between them, it decreases in thickness while passing from the entrance to the exit. Meanwhile its speed gradually increases from the entrance to the exit.

V0 = input velocity Vf = final or output velocity R = roll radius hb = back height hf = output or final thickness

Advanced Manufacturing Process I & II

## Rolling Process

### Roll Gap

V0 = input velocity Vf = final or output velocity R = roll radius hb = back height hf = output or final thickness

=

= angle of bite

L = Roll Gap

Advanced Manufacturing Process I & II

## Rolling Process

### Neutral Point

V0 = input velocity Vf = final or output velocity R = roll radius hb = back height

hf = output or final thickness

 = = angle of bite N-N = neutral point or no-slip point L = Roll Gap

To the left of the Neutral Point:

Velocity of the strip < Velocity of the roll

To the right of the Neutral Point:

Velocity of the strip > Velocity of the roll

Advanced Manufacturing Process I & II

## Rolling Process

### Position of the Neutral Point

As the neutral point reaches the exit, the rolls skid over the strip and the strip will stop moving.

Maximum reduction is given by:

Advanced Manufacturing Process I & II

## Rolling Process

### Simulation

Neutral

Point

R

Roll

hb
hf

Sheet

Back Height (hb):

• 2 mm

Range (0.4mm to 10mm)

Friction Coefficient (µ):

• 0.1 Constant

Flow stress of steel (Yflow)

• 130 Mpa Constant

 Width of the Roller (W): mm 10 Constant Roll Radius (R): mm 75 Constant Rotational speed of Roll: 0.8 m/s Constant

m:

0.1
0.2
0.4

START

 Final sheet thickness (hf): Roll Gap (L): Force/Roller (F): Power/Roller (P):

Enter the parameters and click START.

Advanced Manufacturing Process I & II

## Rolling Process

### Ghosh & Malik, “Manufacturing Science”

Advanced Manufacturing Process I & II

## Rolling Process

The effect of friction on the rolling mill is

 always bad since it retards exit of reduced metal always good since it drags metal into the gap between the rolls advantageous before the neutral point disadvantageous after the neutral point

Advanced Manufacturing Process I & II

## Rolling Process

As compared to cold rolling, hot rolling yields

 better dimensional control and higher strength better dimensional control but poorer strength worse dimensional control and higher strength better dimensional control and poorer strength

Advanced Manufacturing Process I & II

## Rolling Process

Velocity at the exit is

 higher than velocity at the entry lower than velocity at the entry either equal to or lower than velocity at the entry, depending on the coefficient of friction either equal to or higher than velocity at the entry, depending on the coefficient of friction

Advanced Manufacturing Process I & II

## Rolling Process

Power required depends upon

 reduction of thickness width of metal / rolls coefficient of friction metal type

Advanced Manufacturing Process I & II

## Rolling Process

Reducing the rpm of the rolls

 reduces the power required has no affect on the power required affects the power required depending on the coefficient of friction affects the power required depending on the properties of the metal