Roll Pass Design For Bars
Roll Pass Design For Bars
Roll Pass Design For Bars
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TITLE: ROLL PASS DESIGN OF 7/8”( 22 mm ) Date: 14-10-2013
PLAIN, DEFORMED & SQUARE STEEL BARS
CLIENT: Prepared by. Adnan Rev. 0
PROJECT: Checked by.
Approved by. ---- Page 1 of .
Value of s for Roughing Passes,@ 1.0 % = 0.01 x 203.2 = 2.032 mm Let it be = 2 mm Pass No, 1 --5
Value of s for Finishing Passes, @ 0.75 % = 0.0075 x 203.2 = 1.524 mm, Let it be = 1.5 mm Pass 6--8
2- It is decided that how much no of passes are easily possible, how much draught in each pass can be
allowed and what will be the Shape of Passes, for arriving the Product Shape from Initial Material.
Since the Initial Material is Billet 63.5 x 63.5 mm Size of Area = 4000 Sq mm, Billet Corners radii 6mm.
3- The Factor of Coefficient of Contraction on cooling of Rolled Steel Stock is to be added to Hot Size, the X-
Sectional Area of Hot Product will be Computed like, Hot Area = Cold Area x K,
Where, K = 1 + α t and α for Steel = 0.000012 & t = Rolling Temperature of Finishing Pass, 900 ᴼC then
K = 1 + 0.000012 x 900 = 1.0108
Hot Area = 388 x 1.0108 = 392 Sq mm the equivalent Hot Dia = 22.5 mm, will be the actual dia of Rod when it
is coming out of Finishing Pass and will attain its real dia after cooling to atmospheric temperature
= 11.275 %
5- For Distribution of Draught for each Pass, the Stand Position / No is also Considered, in Ist Stand the larger
value of Draught can be allowed due to higher temperature and Larger Angle of Bite but the value of Coefficient
of Friction is lesser due to higher temperature, the Draft is kept lesser and the Roll Pass groove Surface is kept
rough during machining. If Angle of Bite is Larger than Angle of Friction there will be No Rolling as the Stock
will not be accepted by Rolls due to lesser Co-efficient and Angle of Friction. In starting passes slightly lesser
value of draught is applied and is gradually increased and then decreased till the final Pass, which is nearly a
parabolic shape curve. The Roll Pass Schedule is shown below, where all the Parameters are described. This
Roll Pass Schedule is the base of all the Roll Pass Design prepared for a Particular Size Mill and the Product.
This Roll Pass Schedule is being prepared for 7/8” Diameter Round Bar, Deformed Bar & 7/8” Square Bar
with one size Initial Material; Billet 2½” x 2½” Size as Per Mill Layout / Rolling Path of the Product. The Rolling
will commence and Completed in Eight no of Passes which are to be divided over all the Stands. The Direction
of Rotation of Rolls will be such that the Middle Roll of a Three Hi Mill is revolving Anti- Clockwise since it is
Coupled with the Middle Shaft of Pinion Stand which is always Coupled with Output Shaft of Speed Reducing
Gear Box. Also it is such that if the Speed Reducing Gear Box has three Shafts, the output shaft will rotate in
same direction as of Drive Motor. The Direction of Rotation of Electric Drive Motors may also be reversed if it is
required. Over here the Middle Roll of the Three – Hi Mill is revolving Anti-Clockwise. All the Columns, below
are Clear, The Stand No, Pass Location, Relative Stock Movement or Moving Direction and Rolling Position as
well; are noted here the Pass after Rolling may be Turned 90ᴼ this is done in order to Control Width and the
Lateral Spread, is also called Edge wise Rolling.
Pass No 0 1 2 3 4 5 6 7 8
Abbrev
Initial Height hi mm 63.5 63.5 66.33 50.0 55.16 40.0 37.7 23.0 23.223
Draft ∆h mm 0 15.5 16.32 16.0 20.16 9.0 5.2 1.0 0.723
Draft Percent % 0 24.41 30.62 32.0 36.5 22.5 13.8 8.7 3.11
Initial Width bi mm 63.5 63.5 48.0 51.0 34.0 35.0 31.0 23.0 22.0
Lateral Spread ∆b mm 0 2.83 2.977 4.17 5.08 2.711 1.39 0.224 0.5
X- Secn Area A mm² 4,000 3,151 2,518 938 700 565.67 494 401 392
Area Reduced ∆A % 0 21.225 20.0 62.75 25.37 19.18 12.64 18.77 2.24
Shape ----- Square Box Box Diamond Square Diamond Square Oval Round
Stand Position ----- Billet Rough Rough Finish1 Finish1 Finish 2 Finish2 Finish 3 Polish
Pass Location ------ Middle Middle/ Middle / Middle/ Middle Middle/ Middle Middle/
Between Rolls. ----- /Top Bottom Top Bottom / Top Bottom / Top Bottom
Stock ----- ----- Forward Back Forward Back Forward Back Forward Back
Movement
Rolling Position ----- ----- Normal Turn Normal Turn Turn 90ᴼ Turn Turn Turn
/ Flat 90ᴼ /Flat 90ᴼ 90ᴼ 90ᴼ 90ᴼ
The Material to be Rolled is Structural Carbon Steel, Specification ASTM ,A-36 of which Material Composition is
like Carbon = 0.26 %, Manganese = 0.75 %
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PASS NO 1:
Stock Height after Rolling hf = 48.0 mm Co- efficient of Friction for Steel Rolls f = 1.05 – 0.0005 t
Mill Nominal Speed N = 200 R.P.M Nominal Roll Dia D = 203.2 mm ( 0.2032 M )
Angle of No- slip ψ = β/2 – 1/f [ β/2]² = 23.94 /2 x57.3 – 1/ 0.45 [ 23.94 /2 x 57.3]² = 6.41ᴼ
Speed of Stock, Coming Out of Rolls Va = V (1 + S/100 ) = 2.13 ( 1 + 1.77 /100) = 2.168 M/Sec.
Width before Rolling, bi = 63.5 mm Width after Rolling bf = bi + ∆b = 63.5 + 2.83 = 66.33 mm
Cross Sectional Area before Rolling with rounded Corners Ai = 4,000 Sq mm Corners Radii 6 mm
Cross Sectional Area after Rolling with rounded Corners Af = hf x bf = (48 x 66.33 ) - 33 = 3151 Sq mm.
Reduction in Cross Sectional Area, ∆A = ( Ai – Af ) / Ai x 100 =( 4000 – 3151 ) / 4000 x 100 = 21.225%
Length of Arc of Contact between Rolls and the Stock Lc = √ Re x ∆h = √ 90.1 x 15.5 = 37.37 mm.
Viscosity of Metal being Rolled ἠ = 0.01 ( 14 – 0.01 t ) Cv; Cv is 1 for Rolling Speed up to 6 M /Sec.
Co efficient of Friction between Stock & Rolls m = [1.6 f√(Re ∆h) – 1.2 ∆h ] / ( hi + hf )
Rolling Load P = Ps x Ac
Friction Torque Tf = P x f1 x Dn
Drive Power Pd = Pr + Pf / ἠd
Drive Efficiency ἠd = ἠm x ἠg x ἠp
For a 3-Phase Electric Drive Slip Ring Induction Motor the Current Drawn Would be
I = Pe / √3 x E x PF x em.
Electric Load of Pass No 1; I = 149.52 x 1000 /√ 3 x 400 x 0.85 x 0.85 = 299.0 Amps
PASS NO 2:
Stock Height after Rolling hf = 50.0 mm Co- efficient of Friction for Steel Rolls, f = 1.05 – 0.0005 t
Mill Nominal Speed N = 200 R.P.M Nominal Roll Dia D = 203.2 mm ( 0.2032 M )
Angle of No- slip ψ = β/2 – 1/f [ β/2]² = 24.63 /2 x57.3 – 1/ 0.475 [ 24.63 /2 x 57.3]² = 6.74ᴼ
Speed of Stock, Coming Out of Rolls Va = V+ ( V x S/100 ) = 2.13 +( 2.13 x 1.86 /100) = 2.17 M/Sec.
Width before Rolling, bi = 48.0 mm Width after Rolling bf = bi + ∆b = 48.0 + 2.977 = 51.0 mm
Length of Arc of Contact between Rolls and the Stock Lc = √ Re x ∆h = √ 89.6 x 16.3 = 38.21 mm.
Ac = ( 50 + 51 ) / 2 x 38.21 = 1,930 Sq mm
Viscosity of Metal being Rolled ἠ = 0.01 ( 14 – 0.01 t ) Cv; Cv is 1 for Rolling Speed up to 6 M /Sec.
Rolling Load P = Ps x Ac
Friction Torque Tf = P x f1 x Dn
Drive Power Pd = Pr + Pf / ἠd
Drive Efficiency ἠd = ἠm x ἠg x ἠp
For a 3-Phase Electric Drive Slip Ring Induction Motor the Current Drawn Would be;
Electric Load of Pass No 2; I = 181.62 x 1000 /√ 3 x 400 x 0.85 x 0.85 = 363 Amps
PASS NO 3:
Stock Height after Rolling hf = 34.0 mm Co- efficient of Friction for Steel Rolls , f = 1.05 – 0.0005 t
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Mill Nominal Speed N = 200 R.P.M Nominal Roll Dia D = 203.2 mm ( 0.2032 M )
Angle of No- slip ψ = β/2 – 1/f [ β/2]² = 23.86 /2 x 57.3 – 1/ 0.5 [ 23.86 /2 x 57.3]² = 6.96ᴼ
Speed of Stock, Coming Out of Rolls Va = V+ ( V x S/100 ) = 2.13 +( 2.13 x 2.76 / 100) = 2.189 M /Sec.
Cross Sectional Area after Rolling for Diamond Pass, Af =( bf x hf ) / 2 = ( 55.176 x 34 ) / 2 = 938 Sq mm
Length of Arc of Contact between Rolls and the Stock Lc = √ Re x ∆h = √ 93.6 x 16 = 38.7 mm.
Viscosity of Metal being Rolled ἠ = 0.01 ( 14 – 0.01 t ) Cv; Cv is 1 for Rolling Speed up to 6 M /Sec.
Rolling Load P = Ps x Ac
Friction Torque Tf = P x f1 x Dn
Drive Power Pd = Pr + Pf / ἠd ,
For a 3-Phase Electric Drive Slip Ring Induction Motor the Current Drawn Would be;
Electric Load of Pass No 3; I = 206.53 x 1000 /√ 3 x 400 x 0.85 x 0.85 = 413 Amps
This is evident that when adopting a Diamond Shape Pass, we can achieve maximum reduction in Cross
Sectional Area, allowing a small Draught, leading to minimum Rolling Load & Power Consumption. This will
further reduce the No of Passes.
PASS NO 4:
Stock Height after Rolling hf = 35.0 mm Co- efficient of Friction for Steel Rolls, f = 1.05 – 0.0005 t
Angle of No- slip ψ = β/2 – 1/f [ β/2]² = 26.87 /2 x57.3 – 1/ 0.525 [ 26.87 /2 x 57.3]² = 7.434ᴼ
Speed of Stock, Coming Out of Rolls Va = V+ ( V x S/100 ) = 2.13 +( 2.13 x 2.85 /100) = 2.19 M/Sec.
Length of Arc of Contact between Rolls and the Stock Lc = √ Re x ∆h = √ 93.35 x 20.16 = 43.38 mm.
Viscosity of Metal being Rolled ἠ = 0.01 ( 14 – 0.01 t ) Cv; Cv is 1 for Rolling Speed up to 6 M /Sec.
Co efficient of Friction between Stock & Rolls m = 1.6 f√Re ∆h – 1.2 ∆h )/( hi + hf )
Rolling Load P = Ps x Ac
Friction Torque Tf = P x f1 x Dn
Drive Power Pd = Pr + Pf / ἠd ,
Drive Efficiency ἠd = ἠm x ἠg x ἠp
For a 3-Phase Electric Drive Slip Ring Induction Motor the Current Drawn Would be
Electric Load of Pass No 4; I = 202 x 1000 /√ 3 x 400 x 0.85 x 0.85 = 404 Amps
PASS NO 5:
Stock Height after Rolling hf = 31.0 mm Co- efficient of Friction for Steel Rolls , f = 1.05 – 0.0005 t
Angle of No- slip ψ = β/2 – 1/f [ β/2]² = 17.76 /2 x57.3 – 1/ 0.55 [ 17.76 /2 x 57.3]² = 6.38ᴼ
Speed of Stock, Coming Out of Rolls Va = V+ ( V x S/100 ) = 2.13 +( 2.13 x 2.92 /100) = 2.192 M/Sec.
Width before Rolling, bi = 35.0 mm Width after Rolling bf = bi + ∆b = 35.0 + 2.711 = 37.711 mm
Length of Arc of Contact between Rolls and the Stock Lc = √ Re x ∆h = √ 94.35 x 9 = 29.14 mm.
Viscosity of Metal being Rolled ἠ = 0.01 ( 14 – 0.01 t ) Cv; Cv is 1 for Rolling Speed up to 6 M /Sec.
Co efficient of Friction between Stock & Rolls m = (1.6 f√Re ∆h – 1.2 ∆h )/( hi + hf )
Rolling Load P = Ps x Ac
Friction Torque Tf = P x f1 x Dn
Drive Power Pd = Pr + Pf / ἠd ,
Drive Efficiency ἠd = ἠm x ἠg x ἠp
For a 3-Phase Electric Drive Slip Ring Induction Motor the Current Drawn Would be
Electrical Load of Pass No 5; I = 89.05 x 1000 /√ 3 x 400 x 0.85 x 0.85 = 178 Amps
PASS NO 6:
Stock Height after Rolling hf = 32.5 mm Co- efficient of Friction for Steel Rolls , f = 1.05 – 0.0005 t
Angle of No- slip ψ = β/2 – 1/f [ β/2]² = 13.52 /2 x57.3 – 1/ 0.5675 [ 13.52 /2 x 57.3]² = 5.35ᴼ
Speed of Stock, Coming Out of Rolls Va = V+ ( V x S/100 ) = 2.13 +( 2.13 x2.27/100) = 2.17 M/Sec.
Width before Rolling, bi = 31.0 mm Width after Rolling bf = bi + ∆b = 31.0 + 1.39 = 32.39 mm
Area reduced due to rounded corners at a radius of 3 mm = 8 Sq mm is subtracted from cross sectional area.
The Pass has produced a square bar of 7/8” side, this calculation is of a hot Size.
Length of Arc of Contact between Rolls and the Stock Lc = √ Re x ∆h = √ 93.85 x 5.2 = 22.1 mm.
Viscosity of Metal being Rolled ἠ = 0.01 ( 14 – 0.01 t ) Cv; Cv is 1 for Rolling Speed up to 6 M /Sec.
Co efficient of Friction between Stock & Rolls m = (1.6 f √Re ∆h – 1.2 ∆h )/( hi + hf )
Rolling Load P = Ps x Ac
Friction Torque Tf = P x f1 x Dn
Drive Power Pd = Pr + Pf / ἠd ,
Drive Efficiency ἠd = ἠm x ἠg x ἠp
For a 3-Phase Electric Drive Slip Ring Induction Motor the Current Drawn Would be
Electric Load of Pass No 6;I = 69.15 x 1000 /√ 3 x 400 x 0.85 x 0.85 = 138 Amps
PASS NO 7:
The Pass No 6 is rolled out diagonally, these are diagonal dimensions, the Size of Side = 32.5 / √2 = 23.0,
which is the Hot Size, and let it Roll Flatly, so that hi & ho are equal to side of square.
Stock Height after Rolling hf = 22.0 mm Co- efficient of Friction for Steel Rolls f = 1.05 – 0.0005 t
Angle of No- slip ψ = β/2 – 1/f [ β/2]² = 5.835 /2 x57.3 – 1/ 0.585 [ 5.835 /2 x 57.3]² = 1.41ᴼ
Speed of Stock, Coming Out of Rolls Va = V+ ( V x S/100 ) = 2.13 +( 2.13 x 0.255 /100) = 2.135 M/Sec.
Length of Arc of Contact between Rolls and the Stock Lc = √ Re x ∆h = √ 96.475 x 1 = 9.822 mm.
Viscosity of Metal being Rolled ἠ = 0.01 ( 14 – 0.01 t ) Cv; Cv is 1 for Rolling Speed up to 6 M /Sec.
Co efficient of Friction between Stock & Rolls m = (1.6 f√Re ∆h – 1.2 ∆h )/( hi + hf )
Rolling Load P = Ps x Ac
Friction Torque Tf = P x f1 x Dn
Drive Power Pd = Pr + Pf / ἠd ,
For a 3-Phase Electric Drive Slip Ring Induction Motor the Current Drawn Would be
PASS NO 8:
This is the Final or Finish Pass, the dimensions are already determined that the Product Dia is to be 7/8” or
22.225 mm, this size has to be added the allowance for Cooling and reduction to this cold size, which is to be K
= 1+ α t where α = 0.000012 and t = 900 ᴼC, therefore the factor to be multiplied is
K = 1 + 0.000012 x 900
K = 1.0108
The required Size / Pass Dimension will be as per this Hot Dia or 22.5 mm, which after cooling to atmospheric
temperature will be 22.225 mm ( 7/8 ” )
Stock Height after Rolling hf = 22.5 mm Co- efficient of Friction for Steel Rolls , f = 1.05 – 0.0005 t
Angle of No- slip ψ = β/2 – 1/f [ β/2]² = 4.96 /2 x57.3 – 1/ 0.6 [ 4.96 /2 x 57.3]² = 2.3ᴼ
Speed of Stock, Coming Out of Rolls Va = V+ ( V x S/100 ) = 2.13 +( 2.13 x 0.67 /100) = 2.144 M/Sec.
There will be only a shaping in this Pass and a very little reduction in area as well.
Length of Arc of Contact between Rolls and the Stock Lc = √ Re x ∆h = √ 96.35 x 0.723 = 8.346 mm.
Viscosity of Metal being Rolled ἠ = 0.01 ( 14 – 0.01 t ) Cv; Cv is 1 for Rolling Speed up to 6 M /Sec.
Co efficient of Friction between Stock & Rolls m = (1.6 f√Re ∆h – 1.2 ∆h )/( hi + hf )
Rolling Load P = Ps x Ac
Friction Torque Tf = P x f1 x Dn
Drive Power Pd = Pr + Pf / ἠd ,
For a 3-Phase Electric Drive Slip Ring Induction Motor the Current Drawn Would be
Electric Load of Final Pass; I = 11.77 x 1000 /√ 3 x 400 x 0.85 x 0.85 = 24 Amps
The Technical Data of all the Passes is tabulated below. The Passes are shaped and sized as per standard
Rolling Principles and Practices, All Passes selected are of Open Type. The Pass Temperatures are assumed,
may vary during actual practice and the parameters based upon may also vary. The highest Power
Consumption 276.83 HP, in Pass No 3; is within the Power Capacity of Drive Electric Motor, this will save
Energy, Electrical as well as the Thermal One. The famous parameters are entered here, for an easy look over
of the calculated results, these are not realistic results there may be variation as per actual working conditions,
also the sizes and dimensions may need to be changed due to certain other Mill / Work Parameters, any how
this is a very Basic Guide Line to perform a Roll Pass Design for Bars. This Design is prepared for a Three-Hi
Open Train Merchant Type Mill, Size 203.2 mm ( 8.0 in ) only and not to be used for a Continuous Type or any
other size Mill.
Parameters Pass No 0 1 2 3 4 5 6 7 8
Description Abbreviation
Stock Thickness hf mm 63.5 48.0 50.0 34.0 35.0 31.0 32.5 22.0 22.5
Stock Width bf mm 63.5 66.3 51.0 55.17 39.08 37.71 32.39 23.22 22.5
Rolling Temperature t ᴼC ----- 1200 1150 1100 1050 1000 965 930 900
Angle of Bite βᴼ ----- 23.94 24.63 23.86 26.87 17.76 13.52 5.83 4.96
Angle of Friction µᴼ ----- 24.23 25.4 26.56 27.7 28.81 29.46 30.33 31.0
Angle of No Slip Point ψᴼ ----- 6.41 6.74 6.96 7.43 6.38 5.35 1.41 2.3
Forward Slip S% ----- 1.77 1.87 2.189 2.85 2.92 2.042 0.225 0.67
Mean Unit Pressure Ps Kg/mm² ----- 5.4 8.105 8.573 9.943 8.872 12.63 13.3 14.0
Rolling Load P Kgs ----- 13,100 15,642 17,614 15,740 9,399 8,852 3,019 2,578
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Rolling Torque Tr Kg- M ----- 440.43 537.93 613.5 614.52 246.5 176.0 26.68 19.36
Friction Torque Tf Kg-M ----- 129.7 154.86 174.37 155.82 93.05 87.63 29.88 25.52
Rolling Power Pr HP ----- 121.24 148.0 168.88 169.16 67.85 48.46 7.35 5.33
Friction Power Pf HP ----- 35.7 42.63 47.9 42.89 25.6 24.12 8.22 7.0
Drive Power Pd HP ----- 200.44 243.46 276.83 270.82 119.3 92.7 19.89 15.78
Electrical Load I Amps ----- 299 363 413 404 178 138 30 24
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