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Analysis for Stress Prediction in Hot Rolling with Different Process

Parameters by Finite Element Method
Bashishth Kumar Kushwaha 1, B.Moharana2
1Department of Mechanical Engineering, Roorkee Engineering & Management Technology Institute, Shamli, India
2 Department of Mechanical Engineering, DR. B.B.A Government Polytechnic, Karad, (Silvassa),India

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Abstract – In hot rolling mill process the rollers is subjected through the data interactive software Mech/pro to analyze
to heating and cooling cycles with different processing its stress, and then carry out the FEA of the model loaded in
parameter. This nature of heat and processing parameter ANSYS. After Comparing with the material yield limit, the
found some cracks, wear and tear in hot roller. In this work, both stresses are reasonable which will meet the demand of
the study of existing process was done to find the root cause of design. This co-simulation method provides a reliable basis
the cracks in roller mills. The analysis of the rolling process for vertical roller mill design and can also be applied to other
was done and results obtained in terms of equivalent stress mechanical system design process [8]. A coupled thermo-
and effective plastic strain. It has been found that mill speed mechanical finite element method computation on steel pipe
and friction coefficient are the two major factors that rolling process, gets the residual stress and strain change
significantly affect the quality of rolling products. Lower value rule in the rolling process. They analyzed the influence of
of friction coefficient requires that number of mill passes be roller spacing and velocity parameters on residual stress and
increased. Higher value of friction coefficient increases the strain, which provides a reliable theory basis for improving
sticking between rollers and the incoming metal leading to the performance of hot rolling seamless steel pipe and the
defects in steel angle bar. optimization of rolling technological parameters [9]. The roll
Key Words: Hot Rolling, Cold Rolling, Cracks, Coefficient of cross angle, rolling press quantity, intersection position and
Friction, Stress, Strain rolling speed can change the size of the axial force, axial
forces may float small by the pressing ratio increases, lager
1. INTRODUCTION by rolling speed increases, bigger by adding more far
intersection point position, This conclusions have realistic
The sizing press followed by horizontal rolling is more significance in cross rolling schedule making, and provide
efficient in width reduction than deformation by a heavy basis theory reducing rolling axial force [10]. The ring can
edger mill followed by horizontal rolling. The finite-element approximately maintain its round shape at the initial rolling
analysis results for the deformation of a slab also show period, when the process is entering the medium period, the
reasonable agreement with measurements from an actual roundness of the ring becomes worse, and it tends to be
mill test, and from physical modelling experiments [1]. The improved at the final rolling period. A series of ring rolling
effects of process parameters such as the cooling condition experiments were conducted. So the reliability of the finite
of the work-rolls, the rolling speed, and the roll metal element model of the vertical hot ring rolling process with
interfacial heat-transfer coefficient on the temperature measurement and control was validated [11]. The formation
distributions in the work-rolls as well as in the rolling metal. of edge defects in hot strips, resulting from slab corner
The comparison between the model predictions and cracks generated in continuous casting. They developed a
experimental results shows the validity of the proposed model-based concepts for the identification of such initial
model [2]. The rapid development of computer technology slab cracks. To accomplish this task a systematic finite
and the improvement of general finite element analysis element tool Deform-3D was utilized. The numerical results
software, especially with the development of parallel clearly pointed out the significant morphological changes of
computing technique, it has become possible to analyze cold the cracks during rolling and afford valuable indications for a
strip rolling process and calculate the strip deformation with deeper understanding of the underlying process details [12-
3-D finite element contact model of rolls and strip [3]. The 14]. A two dimensional elastic plastic model was used to
temperature of H-beam was a downward trend in the hot simulate the cold rolling of thick strip. They found the speed
rolling process, however, local temperature display rising and diameter of rolls have influence on the quality of rolling
trend, uneven deformation of flange lead to more complex products [15]. The mechanical properties of high strength
temperature distribution, there is certain correlation steel and mild steel at elevated temperatures. They found
between equivalent plastic stress and temperature that yield strength, tensile strength and elastic modulus of
distributions, increasing of equivalent plastic stress as the steels at elevated temperatures decreases [16]. The
temperature increases, research results can provide investigating the mechanism of thermal crack growth while
theoretical basis for rolling regulations and reference of the taking into account the complex thermal and mechanical
production of hot rolling for H-beam [4-7]. The vertical roller interactions during the rolling process. They utilized the
mill 3-D model established in Pro/E is imported into ADAMS concepts of FEM for the estimation of rolls life, from the

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 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056
Volume: 04 Issue: 03 | Mar -2017 www.irjet.net p-ISSN: 2395-0072

perspective of thermal fatigue. Their work described the model for the rolling process [25].Finite element method is
methodology of predicting thermal fatigue crack growth reliable and versatile analytical method that avoids bold
using innovative modelling techniques and they highlights hypothesis, which are often involved in the classical methods
the importance to the operating conditions [17]. The such as the slab method or the energy method [26].
accuracy of the FE model was analysed through a dual
comparison by geometrical and by physical aspects. The
effectiveness of a new numerical subroutine was tested by a
comparison with experimental values acquired from an
industrial plant tool wear, the author characterized the
extent of the tool wear by wear depth. Twenty points were
used to measure tool wear depth with different area
reduction, forming angle, and stretching angle [18].There
was good agreement between experimental results and the
simulation in terms of wear and rolling friction under
different operating conditions. The analysis of disc-disc
interaction has been presented by using FEM technique.
However this work gives rise to thoughts about possible
applications in various fields [19]. The finite element model
for the prediction of the steady-state thermo-mechanical
behaviour of the roll-strip system and of roll life in hot strip
rolling. The model was comprised of basic finite-element (a)
models, which are incorporated into an iterative-solution
procedure to deal with the interdependence between the
thermo-mechanical behavior of the strip and that of the
work roll. However, the model addressed only a part of roll
wear–related problems, leaving the rest for future works
[20]. They used finite element analysis technique to
investigate behavior of rolls related to bending, shifting and
levelling. The effective utilization of these methods, leads
improvisation of the flatness in the cold rolled sheet. Apart
from the profile of sheet, the shape was also significantly
affected by the vibrations developed in mill housing [21].
The developed procedure for the simulation of the hot
rolling process. They stated that rolling is a 3D process but
using the generalized plane strain method, the real 3D
problem can be solved using a 2D Finite Element Model,
saving an important computing time [22]. FEM software are
able to describe the kinetics of recrystallization during the (b)
process, taking into consideration grain size refinement and
grain growth. By incorporating such mathematical models, it
is possible to predict the formation process as a whole,
including the final microstructure obtained for the forged
part, allowing process optimization that focuses on a higher-
quality final product [23]. They developed a computer
system to detect shape defects in the rolled product and
determined the degree of deformation of metal at the design
stage, which allows the initial plans to approximate the final
design as closely as possible. So this system is very helpful
for future researchers, would make it possible to avoid
having to perform a large number of costly and time-
consuming commercial trials and to predict the defects
might be formed in the rolled product [24].The variation of
the blade cross-section, the deformation stress and strain of
the work-piece keep changing during the rolling process and
the conventional rolling theory is no longer valid. The (c)
complexity and diversity of the blade cross-section
determine it impossible to establish a universal theoretical

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(d) Longitudinal Section

Fig:1 The structure of the material after (a) rolling at
7500C, strain 0.14, (b) rolling at 9000C, strain 0.19, (c) Fig: 2 Effect of successive hot rolling particles uniformity
rolling at 10000C, strain 0.2, (d) rolling at 13000C, strain in Al6063-SiC particle size= 152µm [28]
0.18 [27]
In the case of the as-cast slabs, prepared with the application
The investigation of the Fe28Al3Cr iron aluminide of the optimum composite preparation route, the particle
microstructure after rolling with draught of approx. 0.2 was distribution was found to be similar in both longitudinal and
performed both by optical and transmission electron transverse section. Application of successive hot rolling
microscopy. The recrystallized grains after rolling at 10000C resulted in a uniform particle distribution with particle
and 13000C are visible as shown in figure 1. The shape of alignment in the rolling direction [28] as shown in figure 2.
grains after rolling at 750 and 9000C does not enable any
clear interpretation. Transmission electron microscopy 2. PROBLEM DESCRIPTION
provides unambiguous information about the
microstructure [27]. In this work the effective stress and strain is carried out in
steel angle bar during hot rolling operation with optimum
process parameter for prevent the edge crack in angle bar as
shown in figure 3.

Fig 3: Edge Crack

3. RESULTS AND DISCUSSION

The effective stress and strain is carried out in steel angle

Transverse Section bar during hot rolling operation with optimum process
parameter for prevent the edge crack in angle bar. The
diameter of the rollers and temperature of the material were
not changed as per industry requirement. Also limit of mill
speed was taken 110 rpm.
The simulation results were obtained in the terms of
effective plastic strain and effective stress distribution. The
acceptance criteria of plastic strain is 0.5 in hot rolling [29].
So the plastic strain value exceeds this limit then it will lead
edge cracks in steel angle bar.
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Volume: 04 Issue: 03 | Mar -2017 www.irjet.net p-ISSN: 2395-0072

(a)
(a)

(b)
(b)

(c) (c)

Fig. 4: Effective Plastic Strain Distribution in Angle Bar at N=105 Fig. 5 : Effective Plastic Strain Distribution in Angle Bar at N=110
rpm, µ=0.20 (b) µ=0.25 (c) µ=0.30 rpm, (a) µ=0.20 (b) µ=0.25 (c) µ=0.30

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Volume: 04 Issue: 03 | Mar -2017 www.irjet.net p-ISSN: 2395-0072

In this work the ingot and rollers assembly was subjected to

mill speed of 105 and 110 rpm with friction coefficient 0.20,
0.25 and 0.30. The minimum effective plastic strain was
produced 0.5892 at N=105 rpm with friction coefficient 0.20
and maximum effective plastic strain was produced 0.8864
at N=110 rpm (µ=0.20) as shown in figure 6.

(a)

(a)

(b)

(b)

(c)
Fig. 7: Effective Stress Distribution in Angle Bar at N=110 rpm, at
µ=0.20 (b) µ=0.25 (c) µ=0.30
(c)
Fig. 6: Effective Stress Distribution in Angle Bar at N=105 The ingot and rollers assembly was subjected to mill speed
rpm,(a) µ=0.20 (b) µ=0.25 (c) µ=0.30 of 90 rpm, 95 rpm and 100 rpm with friction coefficient 0.20,
0.25 and 0.30. The maximum effective stress was produced

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598.48 MPa at N=105 rpm with friction coefficient 0.30 and The effective plastic strain variation leads to some
minimum effective plastic strain was produced 528.89 MPa interesting observation. The plastic strain is increased or
at N=110 rpm (µ=0.30) as shown in figure 7. decreased between mill speeds 90 to 105 rpm at all
coefficient of friction, but after mill speed 105 rpm, the
plastic strain always increased rapidly as shown in figure 8.

(a)
(a)

(b)
(b)

(c)

Fig. 8: Effective Plastic Strain Variation with Mill Speed at (c)

(a) µ=0.20 (b) µ=0.25 (c) µ=0.30
Fig. 9: Effective Stress Variation with Mill Speed at
µ=0.20 (b) µ=0.25 (c) µ=0.30

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The effective stress variation also leads to some interesting [8] Yazhong sun, Xuming Shao and Zuobing Chen ,“Co-
observation in hot rolling mill operation. The stress simulation Analysis of Vertical Roller Mill Device Based
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The analysis of the rolling process was done and results [10] Xiaokai Wang, Lin Hua, Xinghui Han, Xiaoxuan Wang,
obtained in terms of equivalent stress and effective plastic Dehui Wang & Yali Liu, “Numerical Simulation and
strain. The effects of the friction on the rolling of steel angle Experimental Study on Geometry Variations and Process
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strain. The minimum effective plastic strain was produced [11] Huang Chang-qing, DENG Hua, DIAO Jin-peng and HU
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