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    SME021 - 1P0434Rolling Process

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    abhinav_kssk
    This document outlines an instructional design document for a demo on the rolling process. It includes an introduction to rolling, descriptions of key steps in the rolling process like the roll gap and neutral point, and plans for interactive elements to simulate calculations of maximum reduction and power required for rolling. The demo aims to explain the rolling procedure for a 2-high rolling mill through both animated and interactive pages.

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    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd

    SME021 - 1P0434Rolling Process

    Uploaded by

    abhinav_kssk
    221 views16 pages
    This document outlines an instructional design document for a demo on the rolling process. It includes an introduction to rolling, descriptions of key steps in the rolling process like the roll gap and neutral point, and plans for interactive elements to simulate calculations of maximum reduction and power required for rolling. The demo aims to explain the rolling procedure for a 2-high rolling mill through both animated and interactive pages.

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    SME021_1P0434Rolling Process.ppt

    Original Title

    SME021_1P0434Rolling Process.ppt

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    This document outlines an instructional design document for a demo on the rolling process. It includes an introduction to rolling, descriptions of key steps in the rolling process like the roll gap and neutral point, and plans for interactive elements to simulate calculations of maximum reduction and power required for rolling. The demo aims to explain the rolling procedure for a 2-high rolling mill through both animated and interactive pages.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    221 views16 pages

    SME021 - 1P0434Rolling Process

    Uploaded by

    abhinav_kssk
    This document outlines an instructional design document for a demo on the rolling process. It includes an introduction to rolling, descriptions of key steps in the rolling process like the roll gap and neutral point, and plans for interactive elements to simulate calculations of maximum reduction and power required for rolling. The demo aims to explain the rolling procedure for a 2-high rolling mill through both animated and interactive pages.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 16

    Rolling Process

    Instructional Design Document

    STAM Interactive Solutions

    Demo Outline (For reference)

    Topic Number 1 2 3 4

    Topic Name Introduction Rolling Process Roll Gap Neutral Point

    Page Type Animated page Animated page Animated page Animated page

    5
    6

    Position of Neutral Point


    Simulation

    Animated page
    Interactive page

    Change Log (as per the minutes pdf)


    Changes Suggested by Prof. Ramesh Singh Changes reflected on slide no.

    1
    2

    Start with photo of real roll, voiceover to outline the process


    Follow with schematic diagram listing process parameters (slide 15 of lecture notes at me.iitb.ac.in/~ramesh/me649/rolling.pdf) Show pressure distribution on the schematic (free body diagram / stresses and forces) Introduce neutral point

    Slide 5 Also refer to the notes section


    Slides 6, 7, 8 & 9 Also refer to the notes section

    3 4

    Voiceover to introduce objective of instruction feasibility for reduction / power 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) References Dont cite the wikipedia Add reference books as suggested Modify quiz question 1 - Spelling: affect vs. effect Modify quiz question 4 - All of above should be the correct answer

    Slide 4 Text & Voice over changed Slide10 - Also refer to the notes section

    Slide 11

    Slide 12 & 15

    Rolling Process

    Advanced Manufacturing Process I & II

    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.

    Rolling Process
    Introduction

    Advanced Manufacturing Process I & II

    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

    Advantages: 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

    Rolling Process
    Rolling Process

    Advanced Manufacturing Process I & II

    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

    Rolling Process
    Roll Gap

    Advanced Manufacturing Process I & II

    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

    Rolling Process
    Neutral Point

    Advanced Manufacturing Process I & II

    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

    Rolling Process
    Position of the Neutral Point

    Advanced Manufacturing Process I & II

    As the neutral point reaches the exit, the rolls skid over the strip and the strip will stop moving. Maximum reduction is given by:

    Rolling Process
    Simulation

    Advanced Manufacturing Process I & II

    Back Height (hb): Neutral Point Roll Friction Coefficient ():

    2 mm 0.1

    Range (0.4mm to 10mm)

    Constant

    Flow stress of steel (Yflow) 130 Mpa Constant R Width of the Roller (W):
    10 mm 75 mm Constant Constant

    Roll Radius (R):


    Rotational speed of Roll: hb hf m:

    0.8 m/s Constant


    0.1 0.2 0.4

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

    Enter the parameters and click START.

    Rolling Process
    Resources

    Advanced Manufacturing Process I & II

    Books: Serope Kalpakjian & Steven R. Schmid, Manufacturing Process for Engineering Materials, Section 6.3 Rolling Process Ghosh & Malik, Manufacturing Science

    Rolling Process

    Advanced Manufacturing Process I & II

    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

    Rolling Process

    Advanced Manufacturing Process I & II

    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

    Rolling Process

    Advanced Manufacturing Process I & II

    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

    Rolling Process

    Advanced Manufacturing Process I & II

    Power required depends upon

    reduction of thickness width of metal / rolls


    coefficient of friction metal type

    Rolling Process

    Advanced Manufacturing Process I & II

    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

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