Roll Pass Design For Bars

Download as pdf or txt
Download as pdf or txt
You are on page 1of 20

DESIGN CALCULATION SHEET Issue Work Order.

1
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 .

STEP 1 LAY OUT PLAN, MILL DATA & INITIAL MATERIAL:


We should know the Starting Size & Shape of Initial Material, either the Roll Pass Design can be Started from
Finish ( Product) Size towards the Size of Initial Material, if we do not know behavior, the Mill will show or
otherwise if there is an example present; then can apply that pass design on the same Mill, starting from Billet
Size. Suppose the Initial Material Selected, is Billet 2 1/2” x 2 1/2” ( 63.5 x 63.5 mm ), which will be Rolled to a
Size of 7/8” Bar ( Round Plain & Deformed ) and Square as well. The Material Specification is ASTM A-36.
Over here the Mill Size available Is 8”.Which is an Open Train Merchant Three High Type Rolling Mill, Driven by
an Electric Motor of 300 H.P, through a Speed Reduction Gear Box, Pinion Gear Stand and an Eight Tons
Weight Armed Fly Wheel, the Mill Rotational Speed is 200 RPM having Five No Stands Joined with each other
using Wobbler Spindles and Couplings. The Nominal Rolling Speed is 2.13 M / Sec or ( 7.0 Ft Per Sec ).The
Mill Roll Neck Bearings are Bronze Chocks, Grease Lubricated and Water Spray Cooled. The Material of Rolls
is Carbon Steel.

STEP 2 PREPARATION OF PASS SCHEDULE:


1-The Clearance between two Rolls, s ; is assigned as for Roughing Passes, from 1.0 to 1.5 % of Nominal Roll
Dia and for Finishing Passes, as 0.5 to 1.0 % of Roll Nominal Dia.

The Roll Nominal Dia , D = 203.2 mm ( 8 “ )

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.

Cold Area of Round Bar Dia ( 7/8”) 22 mm = 388 Sq mm

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

4- Total % Reduction in X-Sec’n Area = (4,000 – 392 ) / 4,000 x 100 = 90.2 %

The average Percentage Reduction/ Pass = Total % Reduction in Area / No Of Passes


2

= 90.2/ 8 There are 8 No Passes selected.

= 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.

STEP 3- ROLL PASS DIMENSIONS,SHAPES AND POSITIONS IN MILL STANDS.

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

STEP 4- MATERIAL SPECIFICATION:

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 %
3

Ultimate Tensile Strength = 80,000 PSI

Yield Strength = 36,000 PSI

STEP 5 : ROLL PASS DESIGN CALCULATIONS:

PASS NO 1:

TO BE FLAT ROLLED ( BOX PASS ).

Stock Height before Rolling hi = 63.5 mm Stock Temperature t = 1200ᴼC

Stock Height after Rolling hf = 48.0 mm Co- efficient of Friction for Steel Rolls f = 1.05 – 0.0005 t

Draught ∆h = hi – hf = 15.5 mm 24.41 % f = 1.05 – 0.0005 x 1200

Clearance between Rolls s = 2.0 mm f = 0.45

Effective Roll Dia De = 203.2 – (48 – 2 ) /2 = 180.2 mm Re = 90.1 mm

Angle of Bite β = Cos^-1 ( 1- 15.5 / 180.2) = 23.94ᴼ

Angle of Friction µ = Tan^ -1 f or Tan ^-1 0.45 = 24.23ᴼ

Mill Nominal Speed N = 200 R.P.M Nominal Roll Dia D = 203.2 mm ( 0.2032 M )

Rolling Speed V = π D N /60 = π x 0.2032 x 200 / 60 = 2.13 M / Sec

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

Forward Slip S = Re / hi ( ψ )² = 90.1 / 63.5 ( 6.41 / 57.3 )² x100 = 1.77 %

Speed of Stock, Coming Out of Rolls Va = V (1 + S/100 ) = 2.13 ( 1 + 1.77 /100) = 2.168 M/Sec.

Lateral Spread ∆b = 1.15 ∆h/2 hi [√ (Re ∆h ) - ∆h/2 f]

=1.15 x 15.5/2 x 63.5[√( 90.1 x 15.5) -15.5 /2 x 0.45] = 2.83 mm

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.

Area of Contact Between Stock and Rolls, Ac = ( bi + bf ) / 2 x Lc

Ac = ( 63.5 + 66.33 ) / 2 x 37.37 = 2,426 Sq mm

Unit Resistance to Deformation K = ( 14 – 0.01 t ) ( 1.4 + C + Mn )

K = (14 – 0.01 x 1200 ) ( 1.4 +0.26 + 0.75 ) = 4.82 Kgs / Sq mm


4

Viscosity of Metal being Rolled ἠ = 0.01 ( 14 – 0.01 t ) Cv; Cv is 1 for Rolling Speed up to 6 M /Sec.

ἠ = 0.01 ( 14 – 0.01 x1200 ) x 1 = 0.02 Kg- Sec / Sq mm.

Co efficient of Friction between Stock & Rolls m = [1.6 f√(Re ∆h) – 1.2 ∆h ] / ( hi + hf )

m = [1.6 x 0.45√(90.1 x 15.5) – 1.2 x 15.5]/(63.5 + 48) = 0.12

Mean Rate of Deformation u = 2 Va (√∆h/Re ) / hi+hf

= 2 x 2.168(√15.5 / 90.1) / ( 63.5 + 48 ) = 0.01617 1/ Sec

Mean Unit Pressure of Stock on Rolls, Ps = ( K + ἠu ) ( 1+ m )

Ps = (4.82 +0.02 x 0.01617 ) ( 1+ 0.12 ) = 5.4 Kg / Sq mm

Rolling Load P = Ps x Ac

P = 5.4 x 2,426 = 13,100.4 Kgs

Rolling Torque Tr = 2 x P x a. Kg-M,

a = 0.45 x Lc = 0.45 x 37.37 = 16.81 mm or 0.01681 M

Tr = 2 x 13,100.4 x 0.01681 = 440.435 Kg –M

Rolling Power Pr = 2 π Tr N / 4565

Pr = 2 x π x 440.435 x 200 / 4565 = 121.24 HP

Friction Torque Tf = P x f1 x Dn

Since f1 = 0.075 for Bronze Bearings, Dn = 132 mm or 0.132 M

Tf = 13,100.4 x 0.075 x 0.132 = 129.7 Kg – M

Friction Power Pf = 2 π Tf N / 4565

Pf = 2 x π x 129.7 x 200 / 4565 = 35.7 HP

Drive Power Pd = Pr + Pf / ἠd

Drive Efficiency ἠd = ἠm x ἠg x ἠp

= 0.85 x 0.97 x 0.95 = 0.783

Pd = ( 121.24 + 35.7 ) / 0.783 = 200.44 HP or 149.52 KW

For a 3-Phase Electric Drive Slip Ring Induction Motor the Current Drawn Would be

I = Pe / √3 x E x PF x em.

Pe is Electric Power K.W, I is Current ( Amps ) E is Voltage = 400 Volts

PF is Power Factor =0.85, em is Mech Efficiency of Drive Motor = 0.85


5

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:

TO BE TURNED 90ᴼ AFTER PASS NO1 ( BOX PASS ).

Stock Height before Rolling hi = 66.3 mm Stock Temperature t = 1150ᴼC

Stock Height after Rolling hf = 50.0 mm Co- efficient of Friction for Steel Rolls, f = 1.05 – 0.0005 t

Draught ∆h = hi – hf = 16.3 mm 30.62% f = 1.05 – 0.0005 x 1150

Clearance between Rolls s = 2.0 mm f = 0.475

Effective Roll Dia De = 203.2 – ( 50 – 2 ) /2 = 179.2 mm Re = 89.6 mm

Angle of Bite β = Cos^-1 ( 1- 16.3 / 179.2 ) = 24.63ᴼ

Angle of Friction µ = Tan^ -1 f or Tan ^-1 0.475 ) = 25.4ᴼ

Mill Nominal Speed N = 200 R.P.M Nominal Roll Dia D = 203.2 mm ( 0.2032 M )

Rolling Speed V = π D N /60 = π x 0.2032 x 200 / 60 = 2.13 M / Sec

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

Forward Slip S = Re / hi ( ψ )² = 89.6 / 66.3 ( 6.74 / 57.3 )² x100 = 1.87 %

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.

Spread ∆b = 1.15 ∆h/2 hi [√ (Re ∆h ) - ∆h/2 f]

=1.15 x 16.3/2 x 66.3[√( 89.6 x 16.3) -16.3 /2 x 0.475] = 2.977 mm

Width before Rolling, bi = 48.0 mm Width after Rolling bf = bi + ∆b = 48.0 + 2.977 = 51.0 mm

Cross Sectional Area before Rolling Ai = 3,150 Sq mm ( Area of Pass No 1 )

Cross Sectional Area after Rolling Af = hf x bf =( 50 x 51 ) - 32 = 2,518 Sq mm.

Reduction in Area ∆ A = ( Ai – Af ) / Ai x 100 = ( 3151 – 2,518 ) / 3151 x 100 = 20.0 %

Length of Arc of Contact between Rolls and the Stock Lc = √ Re x ∆h = √ 89.6 x 16.3 = 38.21 mm.

Area of Contact Between Stock and Rolls, Ac = ( bi + bf ) / 2 x Lc

Ac = ( 50 + 51 ) / 2 x 38.21 = 1,930 Sq mm

Unit Resistance to Deformation K = ( 14 – 0.01 t ) ( 1.4 + C + Mn )

K = (14 – 0.01 x 1150 ) ( 1.4 +0.26 + 0.75 ) = 7.23 Kgs / 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.

ἠ = 0.01 ( 14 – 0.01 x1150 ) x 1 = 0.025 Kg- Sec / Sq mm.


6

Co efficient of Friction between Stock & Rolls m = (1.6 f √ Re ∆h – 1.2 ∆h ) / ( hi + hf )

m = (1.6 x 0.475√ 89.6 x 16.3 – 1.2 x 16.3 )/ (66.3 + 50 ) =0.121

Mean Rate of Deformation u = 2 Va (√∆h/Re ) / hi + hf

u = 2 x 2.17 ( √ (16.3 / 89.6 ) / ( 66.3 + 50 ) = 0.016 1/ Sec

Mean Unit Pressure of Stock on Rolls, Ps = ( K + ἠu ) ( 1+ m )

Ps = (7.23 + 0.025 x 0.016 ) ( 1+ 0.121 ) = 8.105 Kg / Sq mm

Rolling Load P = Ps x Ac

P = 8.105 x 1,930 = 15,642.65 Kgs

Rolling Torque Tr = 2 x P x a. Kg-M,

a = 0.45 x Lc = 0.45 x 38.21 = 17.1945 mm or 0.017945 M

Tr = 2 x 15,642.65 x 0.0171945 = 537.935 Kg –M

Rolling Power Pr = 2 π Tr N / 4565

Pr = 2 x π x 537.935 x 200 / 4565 = 148.0 HP

Friction Torque Tf = P x f1 x Dn

Since f1 = 0.075 for Bronze Bearings, Dn = 132 mm or 0.132 M

Tf = 15,642.65 x 0.075 x0.132 = 154.86 Kg – M

Friction Power Pf = 2 π Tf N / 4565

Pf = 2 x π x 154.86 x 200 / 4565 = 42.63 HP

Drive Power Pd = Pr + Pf / ἠd

Drive Efficiency ἠd = ἠm x ἠg x ἠp

= 0.85 x 0.97 x 0.95 = 0.783

Pd = ( 148.0 + 42.63 ) / 0.783 = 243.46 HP or 181.62 KW

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:

TO BE FLAT ROLLED AFTER PASS NO 2 ( DIAMOND PASS ).

Stock Height before Rolling hi = 50.0 mm Stock Temperature t = 1100ᴼC

Stock Height after Rolling hf = 34.0 mm Co- efficient of Friction for Steel Rolls , f = 1.05 – 0.0005 t
7

Draught ∆h = hi – hf = 16.0 mm 32.0 % or f = 1.05 – 0.0005 x 1100

Clearance between Rolls s = 2.0 mm f = 0.5

Effective Roll Dia De = 203.2 – ( 34 – 2 )/ 2 = 187.2 mm Re = 93.6 mm

Angle of Bite β = Cos^-1 ( 1- 16 / 187.2 ) = 23.86ᴼ

Angle of Friction µ = Tan^ -1 f or Tan ^-1 0.5 = 26.565ᴼ

Mill Nominal Speed N = 200 R.P.M Nominal Roll Dia D = 203.2 mm ( 0.2032 M )

Rolling Speed V = π D N /60 = π x 0.2032 x 200 / 60 = 2.13 M / Sec

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

Forward Slip S = Re / hi ( ψ )² = 93.6 / 50 ( 6.96 / 57.3 )² x100 = 2.76 %

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.

Spread ∆b = 1.15 ∆h/2 hi [√ (Re ∆h ) - ∆h/2 f]

=1.15 x 16 /2 x 50 [√( 93.6 x 16 ) – 16 /2 x 0.5] = 4.176 mm

Width before Rolling, bi = 51 mm Width after Rolling bf = bi + ∆b = 51 + 4.176 = 55.176 mm

Cross Sectional Area before Rolling Ai = 2,518 Sq mm ( Area of Pass No 2 )

Cross Sectional Area after Rolling for Diamond Pass, Af =( bf x hf ) / 2 = ( 55.176 x 34 ) / 2 = 938 Sq mm

Reduction in Area ∆A = ( Ai – Af ) / Ai x 100 =( 2,518 – 938 ) / 2,518 x 100 = 62.75 %

Length of Arc of Contact between Rolls and the Stock Lc = √ Re x ∆h = √ 93.6 x 16 = 38.7 mm.

Area of Contact Between Stock and Rolls, Ac = ( bi + bf ) / 2 x Lc

Ac = ( 51 + 55.176 ) / 2 x 38.7 = 2,054.5 Sq mm

Unit Resistance to Deformation K = ( 14 – 0.01 t ) ( 1.4 + C + Mn )

K = (14 – 0.01 x 1100 ) ( 1.4 +0.26 + 0.75 ) = 7.23 Kgs / 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.

ἠ = 0.01 ( 14 – 0.01 x1100 ) x 1 = 0.03 Kg- Sec / Sq mm.

Co efficient of Friction between Stock & Rolls m = (1.6 f √ Re ∆h – 1.2 ∆h ) / ( hi + hf )

m = (1.6 x 0.5√ 93.6 x 16 – 1.2 x 16 ) / ( 50 + 34 ) =0.1857

Mean Rate of Deformation u = 2 Va(√∆h/Re ) / hi+hf

u = 2 x 2.189 ( √ 16 / 93.6 ) / ( 50 + 34 ) = 0.0215 1/ Sec

Mean Unit Pressure of Stock on Rolls, Ps = ( K + ἠu ) ( 1+ m )


8

Ps = (7.23 +0.03 x 0.0215 ) ( 1+ 0.1857 ) = 8.5733 Kg / Sq mm

Rolling Load P = Ps x Ac

P = 8.5733 x 2,054.5 = 17,614.0 Kgs

Rolling Torque Tr = 2 x P x a. Kg-M,

a = 0.45 x Lc = 0.45 x 38.7 = 17.415 mm or 0.017415 M

Tr = 2 x 17,614 x 0.017415 = 613.5 Kg –M

Rolling Power Pr = 2 π Tr N / 4565

Pr = 2 x π x 613.5 x 200 / 4565 = 168.88 HP

Friction Torque Tf = P x f1 x Dn

Since f1 = 0.075 for Bronze Bearings, Dn = 132 mm or 0.132 M

Tf = 17,614 x 0.075 x 0.132 = 174.3786 Kg – M

Friction Power Pf = 2 π Tf N / 4565

Pf = 2 x π x 174.3786 x 200 / 4575 = 47.9 HP

Drive Power Pd = Pr + Pf / ἠd ,

Drive Efficiency ἠd = ἠm x ἠg x ἠp = 0.85 x 0.97 x 0.95 = 0.783

Pd = ( 168.88 + 47.9 ) / 0.783 = 276.85 HP or 206.53 KW

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:

TO BE TURNED 90ᴼ AFTER PASS NO 3( DIAMOND PASS )

Stock Height before Rolling hi = 55.16 mm Stock Temperature t = 1050ᴼC

Stock Height after Rolling hf = 35.0 mm Co- efficient of Friction for Steel Rolls, f = 1.05 – 0.0005 t

Draught ∆h = hi – ho = 20.16 mm 36.5 % or f = 1.05 – 0.0005 x 1050

Clearance between Rolls s = 2.0 mm f = 0.525

Roll Dia De = 203.2 – ( 35 – 2 ) / 2 =186.7 mm Re = 93.35 mm

Angle of Bite β = Cos^-1 ( 1- 20.16 / 186.7 ) = 26.87ᴼ


9

Angle of Friction µ = Tan^ -1 f or Tan ^-1 0.525 = 27.7ᴼ

Mill Speed N = 200 R.P.M Nominal Roll Dia D = 203.2 mm ( 0.2032 M )

Rolling Speed V = π D N /60 = π x 0.2032 x 200 / 60 = 2.13 M / Sec

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

Forward Slip S = Re / hi ( ψ )² = 93.35 / 55.16 ( 7.434 / 57.3 )² x100 = 2.85 %

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.

Spread ∆b = 1.15 ∆h/2 hi [√ (Re ∆h ) - ∆h/2 f]

= 1.15 x 20.16 / 2 x 55.16[√( 93.35 x 20.16) – 20.16/2 x 0.525] = 5.08 mm

Width before Rolling, bi = 34 mm Width after Rolling bf = bi + ∆b = 34 +5.08 =39.08 mm

Cross Sectional Area before Rolling Ai = 938 Sq mm ( Area of Pass No 3 )

Cross Sectional Area of Diamond after Rolling Af = ( hf x bf ) / 2= ( 35 x 40 ) / 2 = 700 Sq mm.

Reduction in Area ∆A = ( Ai – Af ) / Ai x 100 = ( 938 – 700 ) / 938 x 100 = 25.37 %

Length of Arc of Contact between Rolls and the Stock Lc = √ Re x ∆h = √ 93.35 x 20.16 = 43.38 mm.

Area of Contact Between Stock and Rolls, Ac = ( bi + bf ) / 2 x Lc

Ac = ( 34.0 + 39 ) / 2 x 43.38 = 1,583 Sq mm

Unit Resistance to Deformation K = ( 14 – 0.01 t ) ( 1.4 + C + Mn )

K = (14 – 0.01 x 1050 ) ( 1.4 +0.26 + 0.75 ) = 8.435 Kgs / 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.

ἠ = 0.01 ( 14 – 0.01 x1,050 ) x 1 = 0.035 Kg- Sec / Sq mm.

Co efficient of Friction between Stock & Rolls m = 1.6 f√Re ∆h – 1.2 ∆h )/( hi + hf )

m =1.6 x 0.525 √ (93.35 x 20.16 ) – (1.2 x 20.16 ) / (55.16 + 35 ) = 0.1787

Mean Rate of Deformation u = 2 Va (√∆h/Re ) / hi+hf

u = 2 x 2.19 ( √20.16 / 93.35 ) / ( 55.16 +35 ) = 0.02257 1/ Sec

Mean Unit Pressure of Stock on Rolls, Ps = ( K + ἠu ) ( 1+ m )

Ps = (8.435 +0.035x 0.02257 ) ( 1+ 0.1787 ) = 9.943 Kg / Sq mm

Rolling Load P = Ps x Ac

P = 9.943 x 1,583 = 15,740 Kgs

Rolling Torque Tr = 2 x P x a. Kg-M,


10

a = 0.45 x Lc = 0.45 x 43.38 = 19.52 mm or 0.01952 M

Tr = 2 x 15,740 x 0.01952 = 614.52 Kg –M

Rolling Power Pr = 2 π Tr N / 4565

Pr = 2 x π x 614.52 x 200 / 4565 = 169.16 HP

Friction Torque Tf = P x f1 x Dn

Since f1 = 0.075 for Bronze Bearings, Dn = 132 mm or 0.132 M

Tf = 15,740 x 0.075 x0.132 = 155.826 Kg – M

Friction Power Pf = 2 π Tf N / 4565

Pf = 2 x π x 155.826 x 200 / 4575 = 42.89 HP

Drive Power Pd = Pr + Pf / ἠd ,

Drive Efficiency ἠd = ἠm x ἠg x ἠp

= 0.85 x 0.97 x 0.95 = 0.783

Pd = ( 169.16 + 42.89 ) / 0.783 = 270.82 HP or 202.0 KW

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:

TO BE TURNED 90ᴼ AFTER PASS NO 4 ( DIAMOND PASS )

Stock Height before Rolling hi = 40.0 mm Stock Temperature t = 1000ᴼC

Stock Height after Rolling hf = 31.0 mm Co- efficient of Friction for Steel Rolls , f = 1.05 – 0.0005 t

Draught ∆h = hi – ho = 9.0 mm 22.5 % or f = 1.05 – 0.0005 x 1000

Clearance between Rolls s = 2.0 mm f = 0.55

Effective Roll Dia De = 203.2 – ( 31 – 2 ) /2 = 188.7 mm Re = 94.35 mm

Angle of Bite β = Cos^-1 ( 1- 9 / 188.7 ) = 17.76ᴼ

Angle of Friction µ = Tan^ -1 f or Tan ^-1 0.55 = 28.81ᴼ

Mill Speed N = 200 R.P.M Nominal Roll Dia D = 203.2 mm ( 0.2032 M )

Rolling Speed V = π D N /60 = π x 0.2032 x 200 / 60 = 2.13 M / Sec

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

Forward Slip S = Re / hi ( ψ )² = 94.35 / 40 ( 6.38/57.3 )² x100 = 2.92 %


11

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.

Spread ∆b = 1.15 ∆h/2 hi [√ (Re ∆h ) - ∆h/2 f]

=1.15 x 9 / 2 x 40 [√( 94.35 x 9 ) – 9 / 2 x 0.55] = 2.711 mm

Width before Rolling, bi = 35.0 mm Width after Rolling bf = bi + ∆b = 35.0 + 2.711 = 37.711 mm

Cross Sectional Area before Rolling Ai = 700 Sq mm ( Area of Pass No 4 )

Cross Sectional Area of Square after Rolling Af =( hf x bf) / 2

= ( 30 x 37.711 ) / 2 = 565.67 Sq mm.

Reduction in Area ∆ A = ( Ai – Af ) / Ai x 100 =( 700 – 565.67 ) / 700 x 100 = 19.18 %

Length of Arc of Contact between Rolls and the Stock Lc = √ Re x ∆h = √ 94.35 x 9 = 29.14 mm.

Area of Contact Between Stock and Rolls, Ac = ( bi + bf ) / 2 x Lc

Ac = ( 35.0 + 37.711 ) / 2 x 29.14 = 1059.4 Sq mm

Unit Resistance to Deformation K = ( 14 – 0.01 t ) ( 1.4 + C + Mn )

K = (14 – 0.01 x 1000 ) ( 1.4 +0.26 + 0.75 ) = 7.23 Kgs / 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.

ἠ = 0.01 ( 14 – 0.01 x1000 ) x 1 = 0.04 Kg- Sec / Sq mm.

Co efficient of Friction between Stock & Rolls m = (1.6 f√Re ∆h – 1.2 ∆h )/( hi + hf )

m = (1.6 x 0.55√ 94.35 x 9 – 1.2 x 9 )/( 40 + 31 ) = 0.227

Mean Rate of Deformation u = 2 Va(√∆h/Re ) / hi+hf

u = 2 x 2.192 ( √ 9 / 94.35 )/( 40 + 31 ) = 0.019 1/ Sec

Mean Unit Pressure of Stock on Rolls, Ps = ( K + ἠu ) ( 1+ m )

Ps = (7.23 + 0.04 x 0.019 ) ( 1+ 0.227 ) = 8.872 Kg / Sq mm

Rolling Load P = Ps x Ac

P = 8.872 x 1059.4 = 9,399.147 Kgs

Rolling Torque Tr = 2x P x a. Kg-M,

a = 0.45 x Lc = 0.45 x 29.14 = 13.113 mm or 0.013113 M

Tr = 2 x 9,399.147 x 0.013113 = 246.5 Kg –M

Rolling Power Pr = 2 π Tr N / 4565

Pr = 2 x π x 246.5 x 200 / 4565 = 67.855 HP


12

Friction Torque Tf = P x f1 x Dn

Since f1 = 0.075 for Bronze Bearings, Dn = 132 mm or 0.132 M

Tf = 9,399.147 x 0.075 x 0.132 = 93.05 Kg – M

Friction Power Pf = 2 π Tf N / 4565

Pf = 2 x π x 93.05 x 200 / 4565 = 25.6 HP

Drive Power Pd = Pr + Pf / ἠd ,

Drive Efficiency ἠd = ἠm x ἠg x ἠp

= 0.85 x 0.97 x 0.95 = 0.783

Pd = ( 67.855 + 25.6 ) / 0.783 = 119.35 HP or 89.05 KW

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:

TO BE TURNED 90ᴼ AFTER PASS NO 5 ( SQUARE PASS )

Stock Height before Rolling hi = 37.7 mm Stock Temperature t = 965ᴼC

Stock Height after Rolling hf = 32.5 mm Co- efficient of Friction for Steel Rolls , f = 1.05 – 0.0005 t

Draught ∆h = hi – ho = 5.2 mm 13.8 % or f = 1.05 – 0.0005 x 965

Clearance between Rolls s = 1.5 mm f = 0.5675

Effective Roll Dia De = 203.2 – ( 32.5 – 1.5 ) / 2 = 187.7 mm Re = 93.85 mm

Angle of Bite β = Cos^-1 ( 1- 5.2 / 187.7 ) = 13.52ᴼ

Angle of Friction µ = Tan^ -1 f or Tan ^-1 0.565 = 29.46ᴼ

Mill Speed N = 200 R.P.M Nominal Roll Dia D = 203.2 mm ( 0.2032 M )

Rolling Speed V = π D N /60 = π x 0.2032 x 200 / 60 = 2.13 M / Sec

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

Forward Slip S = Re / hi ( ψ )² = 93.85 / 37.7 ( 5.35 / 57.3 )² x100 = 2.042 %

Speed of Stock, Coming Out of Rolls Va = V+ ( V x S/100 ) = 2.13 +( 2.13 x2.27/100) = 2.17 M/Sec.

Spread ∆b =1.15 ∆h/2 hi [√ (Re ∆h ) - ∆h/2 f]

=1.15 x 5.2 / 2 x 37.7 [√( 93.85 x 5.2 ) – 5.2 /2 x 0.5675 ] = 1.39 mm


13

Width before Rolling, bi = 31.0 mm Width after Rolling bf = bi + ∆b = 31.0 + 1.39 = 32.39 mm

Cross Sectional Area before Rolling Ai = 565.5 Sq mm ( Area of Pass No 5 )

Cross Sectional Area of Diamond Pass after Rolling Af = hf x bf = ( 31 x 32.39 ) / 2 – 8 = 494 Sq 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.

Reduction in Area ∆ A = ( Ai – Af ) / Ai x 100 =( 565.5 – 494 ) / 565.5 x 100 = 12.64 %

Length of Arc of Contact between Rolls and the Stock Lc = √ Re x ∆h = √ 93.85 x 5.2 = 22.1 mm.

Area of Contact Between Stock and Rolls, Ac = ( bi + bf ) / 2 x Lc

Ac = ( 31 + 32.39 ) / 2 x 22.1 = 700.46 Sq mm

Unit Resistance to Deformation K = ( 14 – 0.01 t ) ( 1.4 + C + Mn )

K = (14 – 0.01 x 965 ) ( 1.4 +0.26 + 0.75 ) = 10.4835 Kgs / 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.

ἠ = 0.01 ( 14 – 0.01 x 965 ) x 1 = 0.0435 Kg- Sec / Sq mm.

Co efficient of Friction between Stock & Rolls m = (1.6 f √Re ∆h – 1.2 ∆h )/( hi + hf )

m = (1.6 x 0.5675√ 93.85 x 5.2 – 1.2 x 5.2 )/(37.7 +32.39) = 0.2054

Mean Rate of Deformation u = 2 Va (√∆h/Re ) / hi+hf

u = 2 x 2.173 ( √ 5.2 / 93.85) / ( 37.7 + 32.39 ) = 0.0146 1/ Sec

Mean Unit Pressure of Stock on Rolls, Ps = ( K + ἠu ) ( 1+ m )

Ps = (10.4835 +0.0435 x 0.0146 ) ( 1+ 0.2054 ) = 12.6375 Kg / Sq mm

Rolling Load P = Ps x Ac

P = 12.6375 x 700.46 = 8,852.11 Kgs

Rolling Torque Tr = 2 x P x a. Kg-M,

a = 0.45 x Lc = 0.45 x 22.1 = 9.945 mm or 0.009945 M

Tr = 2 x 8,852.11 x 0.0992 = 176.068 Kg –M

Rolling Power Pr = 2 π Tr N / 4565

Pr = 2 x π x 176.068 x 200 / 4565 = 48.46 HP

Friction Torque Tf = P x f1 x Dn

Since f1 = 0.075 for Bronze Bearings, Dn = 132 mm or 0.132 M


14

Tf = 8,852.11 x 0.075 x 0.132 = 87.635 Kg – M

Friction Power Pf = 2 π Tf N / 4565

Pf = 2 x π x 87.635 x 200 / 4575 = 24.12 HP

Drive Power Pd = Pr + Pf / ἠd ,

Drive Efficiency ἠd = ἠm x ἠg x ἠp

= 0.85 x 0.97 x 0.95 = 0.783

Pd = ( 48.46 + 24.12 ) / 0.783 = 92.7 HP or 69.15 KW

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:

TO BE FLAT ROLLED 90ᴼ AFTER PASS NO 6 ( OVAL PASS ).

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 before Rolling hi = 23.0 mm Stock Temperature t = 930ᴼC

Stock Height after Rolling hf = 22.0 mm Co- efficient of Friction for Steel Rolls f = 1.05 – 0.0005 t

Draught ∆h = hi – ho = 1.0 mm 8.7 % or f = 1.05 – 0.0005 x 930

Clearance between Rolls s = 1.5 mm f = 0.585

Effective Roll Dia De = 203.2 – ( 22 – 1.5 ) / 2 = 192.95 mm Re = 96.475 mm

Angle of Bite β = Cos^-1 ( 1- 1 / 192.95 ) = 5.835ᴼ

Angle of Friction µ = Tan^ -1 f or Tan ^-1 0.585 = 30.33ᴼ

Mill Speed N = 200 R.P.M Nominal Roll Dia D = 203.2 mm ( 0.2032 M )

Rolling Speed V = π D N /60 = π x 0.2032 x 200 / 60 = 2.13 M / Sec

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

Forward Slip S = Re / hi ( ψ )² = 96.475 / 23 ( 1.41 /57.3 )² x100 = 0.255 %

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.

Spread ∆b =1.15 ∆h/2 hi [√ (Re ∆h ) - ∆h/2 f]

=1.15 x 1 /2 x 23[√( 96.475 x 1 ) - 1 / 2 x 0.585] = 0.224 mm

Width before Rolling, bi = 23 mm Width after Rolling bf = bi + ∆b =23 + 0.224 = 23.224 mm


15

Cross Sectional Area before Rolling Ai = 494 Sq mm ( Area of Pass No 6 )

Cross Sectional Area of Oval after Rolling Af = π x bf/2 x hf/2 = 401 Sq mm

Reduction in Area ∆ A = ( Ai – Af ) / Ai x 100 =( 494 – 401 ) / 494 x 100 =18.77 %

Length of Arc of Contact between Rolls and the Stock Lc = √ Re x ∆h = √ 96.475 x 1 = 9.822 mm.

Area of Contact Between Stock and Rolls, Ac = ( bi + bf ) / 2 x Lc

Ac = ( 23 + 23.224 ) / 2 x 9.822 = 227.0 Sq mm

Unit Resistance to Deformation K = ( 14 – 0.01 t ) ( 1.4 + C + Mn )

K = (14 – 0.01 x 930 ) ( 1.4 +0.26 + 0.75 ) = 11.327 Kgs / 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.

ἠ = 0.01 ( 14 – 0.01 x 930 ) x 1 = 0.047 Kg- Sec / Sq mm.

Co efficient of Friction between Stock & Rolls m = (1.6 f√Re ∆h – 1.2 ∆h )/( hi + hf )

m = (1.6 x 0.585 √ 96.475 x 1 – 1.2 x 1) /( 23.224 + 23 ) =0.1745

Mean Rate of Deformation u = 2 Va (√∆h/Re ) / hi+hf

= 2 x 2.136 (√1 / 96.475) / ( 23.223 +23 ) = 0.0094 1/ Sec

Mean Unit Pressure of Stock on Rolls, Ps = ( K + ἠu ) ( 1+ m )

Ps = (11.327 + 0.047 x 0.0094 ) ( 1+ 0.1745 ) = 13.3 Kg / Sq mm

Rolling Load P = Ps x Ac

P = 13.3 x 227 = 3,019.1 Kgs

Rolling Torque Tr = 2x P x a. Kg-M,

a = 0.45 x Lc = 0.45 x 9.8 = 4.42 mm or 0.00442 M

Tr = 2 x 3,019.1 x 0.00442 =26. 688 Kg –M

Rolling Power Pr = 2 π Tr N / 4565

Pr = 2 x π x 26.688 x 200 / 4565 = 7.35 HP

Friction Torque Tf = P x f1 x Dn

Since f1 = 0.075 for Bronze Bearings, Dn = 132 mm or 0.132 M

Tf = 3,019.1 x 0.075 x0.132 = 29.889 Kg – M

Friction Power Pf = 2 π Tf N / 4565

Pf = 2 x π x 29.889 x 200 / 4575 = 8.22 HP


16

Drive Power Pd = Pr + Pf / ἠd ,

Drive Efficiency ἠd = ἠm x ἠg x ἠp = 0.85 x 0.97 x 0.95 = 0.783

Pd = ( 7.35 + 8.22 ) / 0.783 = 19.8945 HP or 14.84 KW

For a 3-Phase Electric Drive Slip Ring Induction Motor the Current Drawn Would be

Electric Load of Pass No 7; I = 14.84 x 1000 /√ 3 x 400 x 0.85 x 0.85 = 30 Amps

PASS NO 8:

TO BE TURNED 90ᴼ AFTER PASS NO 7 ( ROUND PASS ).

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

Or Hot Size Dia = 22.225 x 1.0108 = 22.5 mm.

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 before Rolling hi = 23.22 mm Stock Temperature t = 900ᴼC

Stock Height after Rolling hf = 22.5 mm Co- efficient of Friction for Steel Rolls , f = 1.05 – 0.0005 t

Draught ∆h = hi – ho = 0.723 mm 3.11 % or f = 1.05 – 0.0005 x 900

Clearance between Rolls s = 1.5 mm f = 0.6

Effective Roll Dia De = 203.2 – ( 22.5 - 1.5 ) / 2 = 192.7 mm Re = 96.35 mm

Angle of Bite β = Cos^-1 ( 1 – 0.723 / 192.7) = 4.96ᴼ

Angle of Friction µ = Tan^ -1 f or Tan ^-1 0.6 = 31 ᴼ

Mill Speed N = 200 R.P.M Nominal Roll Dia D = 203.2 mm ( 0.2032 M )

Rolling Speed V = π D N /60 = π x 0.2032 x 200 / 60 = 2.13 M / Sec

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

Forward Slip S = Re / hi ( ψ )² = 96.35 / 23.223 ( 2.3 / 57.3 )² x100 = 0.67 %

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.

Spread ∆b =1.15 ∆h/2 hi [√ (Re ∆h ) - ∆h/2 f]

=1.15 x 0.723 /2 x 23.223[√( 96.35x 0.723 ) – 0.723 /2 x 0.6] =0.5 mm


17

Width before Rolling, bi = 22.0 mm Width after Rolling bf = bi + ∆b = 22 + 0.5 = 22.5 mm

Cross Sectional Area before Rolling Ai = 401 Sq mm ( Area of Pass No 7 )

Since Now hf = Dia of Bar at temp 900ᴼC, =22.5 mm

Cross Sectional Area after Rolling Af = π /4 x ( hf )² = 392 Sq mm.

Reduction in Area = ( Ai – Af ) / Ai x 100 =( 401 – 392 ) / 401 x 100 = 2.24 %

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.

Area of Contact Between Stock and Rolls, Ac = ( bi + bf ) / 2 x Lc

Ac = ( 22 + 22.135 ) / 2 x 8.346 = 184 Sq mm

Unit Resistance to Deformation K = ( 14 – 0.01 t ) ( 1.4 + C + Mn )

K = (14 – 0.01 x 900 ) ( 1.4 +0.26 + 0.75 ) = 12.05 Kgs / 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.

ἠ = 0.01 ( 14 – 0.01 x 900 ) x 1 = 0.05 Kg- Sec / Sq mm.

Co efficient of Friction between Stock & Rolls m = (1.6 f√Re ∆h – 1.2 ∆h )/( hi + hf )

m = (1.6 x 0.6√ 96.35 x 0.723 – 1.2 x 0.723 )/( 22 + 22.135) = 0.1626

Mean Rate of Deformation u = 2 Va(√∆h/Re ) / hi+hf

u = 2 x 2.144 ( √ 0.723 / 96.35) / ( 22 + 22.135 ) = 0.008416 1/ Sec

Mean Unit Pressure of Stock on Rolls, Ps = ( K + ἠu ) ( 1+ m )

Ps = (12.05 +0.05 x 0.008416 ) ( 1+ 0.1626 ) = 14.00 Kg / Sq mm

Rolling Load P = Ps x Ac

P =14 x 184 = 2,578 Kgs

Rolling Torque Tr = 2x P x a. Kg-M,

a = 0.45 x Lc = 0.45 x 8.346 = 3.756 mm or 0.003756 M

Tr = 2 x 2,578 x 0.003756 = 19.36 Kg –M

Rolling Power Pr = 2 π Tr N / 4565

Pr = 2 x π x 19.36 x 200 / 4565 = 5.33 HP

Friction Torque Tf = P x f1 x Dn

Since f1 = 0.075 for Bronze Bearings, Dn = 132 mm or 0.132 M


18

Tf = 2,578 x 0.075 x0.132 = 25.52 Kg – M

Friction Power Pf = 2 π Tf N / 4565

Pf = 2 x π x 25.52 x 200 / 4565 = 7.0 HP

Drive Power Pd = Pr + Pf / ἠd ,

Drive Efficiency ἠd = ἠm x ἠg x ἠp = 0.85 x 0.97 x 0.95 = 0.783

Pd = ( 5.33 + 7 ) / 0.783 = 15.78 HP or 11.77 KW

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

STEP 6-TECHNICAL DATA OF PASSES:

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
19

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
20

You might also like