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Rolling Force, Torque and Power: Bulk Deformation Processes S. Mukhopadhyay

The document discusses rolling force, torque, and power calculations. It presents equations for computing the rolling force as the integral of friction over the contact angle. It also gives an equation for rolling torque as the integral of friction times the radius. The document notes that subtracting two large terms in the original torque equation can lead to numerical errors. It then presents an alternate method for calculating an effective frictional force based on the stress distribution under the work rolls. This effective friction force can then be used to compute torque and power more accurately.

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Sahil Sunda
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© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
72 views

Rolling Force, Torque and Power: Bulk Deformation Processes S. Mukhopadhyay

The document discusses rolling force, torque, and power calculations. It presents equations for computing the rolling force as the integral of friction over the contact angle. It also gives an equation for rolling torque as the integral of friction times the radius. The document notes that subtracting two large terms in the original torque equation can lead to numerical errors. It then presents an alternate method for calculating an effective frictional force based on the stress distribution under the work rolls. This effective friction force can then be used to compute torque and power more accurately.

Uploaded by

Sahil Sunda
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Rolling force, torque and power


 The total force trying to separate the rolls are obtained by integrating the 
vertical component of the forces acting on the interface. 
 Angle 𝜃 is very small, vertical component of friction neglected.

𝐹 𝑝𝑅 cos 𝜃𝑑𝜃 𝑝𝑅𝑑𝜃 𝑝 𝑅𝑑𝜃 𝑝 𝑅𝑑𝜃

 The above integrations are generally computed numerically.

 Rolling torque for each roll is given by:

𝑇 𝜇𝑝𝑅 𝑑𝜃 𝜇𝑝 𝑅 𝑑𝜃 𝜇𝑝 𝑅 𝑑𝜃

Negative sign due to friction direction reversal after neutral point.

S. Mukhopadhyay Bulk Deformation Processes


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Rolling force, torque and power


The previous expression is prone to numerical errors due to subtraction of two 
large terms.
𝑝
𝐹
 An alternate method

𝜎 ℎ 𝜎 ℎ

𝑝 𝐹

Considering equilibrium of the working area , an effective frictional force 𝐹 is 
established:

𝐹 𝜎 ℎ 𝜎 ℎ 2 𝑝𝑅 sin 𝜃𝑑𝜃 𝜎 ℎ 𝜎 ℎ 2 𝑝𝑅𝜃𝑑𝜃

1
𝑇 𝐹𝑅 𝜎 ℎ 𝜎 ℎ 𝑅 𝑝𝑅 𝜃𝑑𝜃 Power 𝑃 𝑇𝜔
2

S. Mukhopadhyay Bulk Deformation Processes


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Worked examples

1.

S. Mukhopadhyay Bulk Deformation Processes


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S. Mukhopadhyay Bulk Deformation Processes


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2.

S. Mukhopadhyay Bulk Deformation Processes


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S. Mukhopadhyay Bulk Deformation Processes


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S. Mukhopadhyay Bulk Deformation Processes


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Rolling Defects

Wavy edges Cracks Alligatoring


 Result of roll bending,   Result of poor metal   Due to presence of defects 
strip is thinner and  ductility at the rolling  in the original cast material 
elongate more than at  temperature. or due to nonuniform bulk 
the centre. deformation

Roll‐bending and its solution using cambered rolls

(a) (b)
Residual stress in rolling (a) small rolls/ small thickness 
reduction(b) large rolls/large thickness reduction

S. Mukhopadhyay Bulk Deformation Processes

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