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Roll Power: How Much Power Is Required To Run The Rollers?

This document discusses the power required to run rollers in a rolling process. It provides equations to calculate the power per roll (P) and the total mill power for two rolls, where P is a function of the width, rotation velocity, and roll diameter. An example problem is then presented to calculate the power input in kW required for rolling a sheet of aluminum alloy using given values for sheet width, thickness reduction, material properties, roll diameter, and rotation rate. A follow up question asks the reader to calculate the mass flow rate of aluminum produced per second using the density of the alloy.

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101 views18 pages

Roll Power: How Much Power Is Required To Run The Rollers?

This document discusses the power required to run rollers in a rolling process. It provides equations to calculate the power per roll (P) and the total mill power for two rolls, where P is a function of the width, rotation velocity, and roll diameter. An example problem is then presented to calculate the power input in kW required for rolling a sheet of aluminum alloy using given values for sheet width, thickness reduction, material properties, roll diameter, and rotation rate. A follow up question asks the reader to calculate the mass flow rate of aluminum produced per second using the density of the alloy.

Uploaded by

Foley Omoniyi
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Roll Power

How much power is required to run P


the rollers?
Roll Power
The power P (in watts) required, per
roll, to continuously roll the strip is: Note:
= width
P = rotation velocity
where ω is in rad/s.

The power per roll can equivalently be


given in terms of N (in RPM) as:

Therefore the total mill power


(for two rolls) is:
Example: Sheet Rolling Power
A sheet of aluminium alloy, 1 m wide, is being rolled from a
thickness of 20 mm to one of 15 mm. The uniaxial yield strength of
the alloy is 300 MPa. The diameter of the rolls are 600 mm, and
they rotate at 30 RPM. Calculate the power input required for the
process, in kW.

3
Example: Sheet Rolling Power
A sheet of aluminium alloy, 1 m wide, is being rolled from a
thickness of 20 mm to one of 15 mm. The uniaxial yield strength of
the alloy is 300 MPa. The diameter of the rolls are 600 mm, and
they rotate at 30 RPM. Calculate the power input required for the
process, in kW.

Answer:
F = 13.420 MN
T = 260 kNm
P = 816.8 kW
P_total = 2*P = 1,633.6 kW 4
Example: Sheet Rolling Power
Follow on question: given that the aluminium alloy has a density
of 2.7 g\cm3, what is the mass flow rate (in kg/s) of the aluminium?
i.e. what mass of aluminium is produced per second?

5
Sticking versus slipping friction

D.J. Browne Advanced Metals Processing


Sticking vs. slipping friction

v
What shape will the deformed
block of material take?
workpiece

It depends on the friction at


tool
the workpiece/tool interface…

7
Sticking vs. slipping friction
v

slipping
v

In many cases, there will be sticking

both regions of stick and


regions of slip 8
Sticking or Slipping?
The shear/friction force is t.

k is the shear strength of the alloy being deformed.


v
If t > k à sticking friction.
t
The workpiece sticks to the tool surface, and shear
within the alloy occurs.

• occurs at high µ (rough tool surface, no


lubrication).
• occurs at low k or s0 (e.g. at high T)
v

In rolling:
• slipping: forward and backwards slip except at
sticking
neutral point
• sticking: surface of the sheet/plate sticks to the
9
surface of the roll along the contact length.

D.J. Browne Advanced Metals Processing


Flat and shape rolling

10
11
Calculation of Hot Rolling Loads
Procedure:
𝐹 = 𝜎#!∗ . 𝑤. 𝑅𝛿. 𝑄
1. Find % reduction, or the strain.
2. Determine mean strain rate.
3. Read flow stress from experimental curves at the appropriate temperature.
4. Calculate the contact area.
5. Determine the value of the geometric factor Q.
6. Calculate the load on the machine.

D.J. Browne Advanced Metals Processing 12


Calculation of Hot Rolling Loads
Procedure:
𝐹 = 𝜎#!∗ . 𝑤. 𝑅𝛿. 𝑄
1. Find % reduction, or the strain.
2. Determine mean strain rate.
3. Read flow stress from experimental curves at the appropriate temperature.
4. Calculate the contact area.
5. Determine the value of the geometric factor Q.
6. Calculate the load on the machine. Resistance to homogeneous deformation of
commercially pure aluminium when deformed at
various strain rates and temperatures.

55 MPa
12.5 MPa

𝜎#!

D.J. Browne Advanced Metals Processing 13


Calculation of Hot Rolling Loads
𝐹 = 𝜎#!∗ . 𝑤. 𝑅𝛿. 𝑄
Read flow stress from experimental curves at the appropriate temperature.

D.J. Browne Advanced Metals Processing 14


Calculation of Hot Rolling Loads
Procedure:
𝐹 = 𝜎#!∗ . 𝑤. 𝑅𝛿. 𝑄
1. Find % reduction, or the strain.
2. Determine mean strain rate.
3. Read flow stress from experimental curves at the appropriate temperature.
4. Calculate the contact area.
5. Determine the value of the geometric factor Q.
6. Calculate the load on the machine.

Q for different ratios of roll radius (R) to incoming


strip thickness (h1), and percentage reduction in
thickness.

D.J. Browne Advanced Metals Processing 15


Calculation of Hot Rolling Loads
Procedure:
𝐹 = 𝜎#!∗ . 𝑤. 𝑅𝛿. 𝑄
1. Find % reduction, or the strain.
2. Determine mean strain rate.
3. Read flow stress from experimental curves at the appropriate temperature.
4. Calculate the contact area.
5. Determine the value of the geometric factor Q.
6. Calculate the load on the machine.

Strain rate calculation will depend on whether we have slipping or sticking friction.

For hot rolling, roll surface is rough (high t) and alloy temperature is high (low k), so we expect
sticking friction.

Recall: if t > k à sticking friction

D.J. Browne Advanced Metals Processing 16


Calculation of Hot Rolling Loads
Procedure:
𝐹 = 𝜎#!∗ . 𝑤. 𝑅𝛿. 𝑄
1. Find % reduction, or the strain.
2. Determine mean strain rate.
3. Read flow stress from experimental curves at the appropriate temperature.
4. Calculate the contact area.
5. Determine the value of the geometric factor Q.
6. Calculate the load on the machine.

Strain rate calculation will depend on whether we have slipping or sticking friction.

For hot rolling, roll surface is rough (high t) and alloy temperature is high (low k), so we expect
sticking friction.

Recall: if t > k à sticking friction

See handout (notes) on calculation of strain rates in rolling, for both sticking a slipping
friction cases ….

D.J. Browne Advanced Metals Processing 17


Industrial Cold Rolling Plant

www.ifm.com

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